Cutter mounting systems and cutters for the same

ABSTRACT

A cutter includes a first end configured to engage an object along a dominant force vector, a second end opposite the first end, a first side, and a second side opposite the first side. The cutter further includes an outer side, an inner side, and an aperture extending from the outer side to the inner side along a fastener axis that is substantially perpendicular to the dominant force vector. The cutter also includes a cutter tip on the first end and having a first cutting edge, a second cutting edge, and a third cutting edge, the cutting edges defining therebetween a cutting face. The cutting face defines a cutting swath having a width between the first cutting edge and the second cutting edge as the cutter rotates with the apparatus. No portion of the first side or the second side extends outside the width of the cutting swath.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/627,377 filed Feb. 7, 2018, and further claims thebenefit of U.S. Provisional Patent Application No. 62/661,476 filed Apr.23, 2018. The entire content of these provisional patent applications ishereby incorporated by reference herein.

BACKGROUND

The present disclosure relates generally to material reduction machinesand processing tools (e.g., cutters) that are adapted to remove itemssuch as tree stumps. Various methods and machines for removing orreducing the size of stumps are known. Examples of stump reductionmachines are disclosed in U.S. Pat. No. 6,014,996 titled “Control Systemfor Stump Cutters” assigned to Vermeer; U.S. Pat. No. 7,011,124 titled“Stump Grinder Having Automatic Reversing Feed Assembly” assigned toTramor; U.S. Pat. No. 6,026,871 titled “Stump Cutter Safety System”assigned to Rayco; and U.S. Pat. No. 6,230,770 titled “Stump Chipper andMethod for the Operation Thereof” assigned to Vermeer-Holland. Aspectsdiscussed herein also apply to material reduction machines that use adrum, such as horizontal grinders, tub grinders, or mulchers like thosediscussed in U.S. Pat. Nos. 6,843,435; and 5,950,942.

Many material reduction machines use cutters (with ‘teeth’) asprocessing tools for material reduction. Some examples of existingcutters are Vermeer® Yellow Jackets™, Rayco® Super Teeth, and Bandit®Beast® knife style cutters. Some of these cutter tooth mounting systemsplace any excessive cutting load through the mounting bolts in shear(greater than what the frictional force between the cutter and the driveplate can support). The result is broken bolts and tips, but moreimportantly wheel bolt holes become misshapen (sometimes referred to as“egged out”). The result is a worsening joint between the cutter andcutter wheel that is more prone to repeat failures and eventuallyrequires replacement of the cutter, cutter wheel, or both.

FIGS. 54A-D illustrate one type of Bandit® Beast® cutter assembly 5 andthe arrangement of the cutter assembly 5 on a cutter drum 15. As shownin FIG. 54A, the cutter assembly 5 has a cutter 10 that is mounted ontothe cutter drum 15 via a mounting bracket 20. The mounting bracket 20 iscurved to conform to the outer shape of the cutter drum 15, and isgenerally secured to the cutter drum 15 via welding or similarattachment means. The mounting bracket 20 has a post 25 that extendsgenerally upward (in the same plane as the drum 15), and the cutter 10is coupled to the post 25 via alignment of a hole in the cutter 10 withthe post. A nut 30 secures the cutter 10 to the mounting bracket 20.With reference to FIGS. 54C and 54D, the cutter 10 has a mountingsurface 35 that is generally planar and that mates with a correspondingsurface 40 on the mounting bracket 20. The cutter 10 also has anextension 45 that mates with a front edge 50 of the mounting bracket 20.FIGS. 54B-54D illustrate how the cutter assembly 5—the cutter 10 and themounting bracket 20—is arranged on the cutter drum 15 relative to aplane 55 extending through the rotational center of the cutter drum 15.While the cutter assembly is shown at the top of the cutter drum 15, andthe plane 55 is shown as a vertical plane, this is only for purposes ofsimplicity in describing the existing Bandit® Beast® system. It will beunderstood that, at the point of impact of the cutter 10 with an object(e.g., a stump), the plane 55 may be oriented other than vertical (e.g.,horizontal or angled downward relative to horizontal). The dominantforce vector 60 at the point of impact is tangential to the circlerepresenting the cutter drum 15.

FIGS. 54C and 54D illustrate the Bandit® Beast® cutter assembly to moreclearly show the orientation of the cutter 10 relative to the plane 55and the dominant force vector 60 at the point of impact of the cutter 10on an object. More specifically, a plane 65 defined by the mountingsurface is non-parallel to the dominant force vector 60. The front ofthe cutter edge 70 on the cutter 10 is in a plane 72 with a rake angle75 (e.g., approximately 5-15°) that is backward relative to thedirection of travel (shown by arrow 80). In this orientation, the cutter10 is susceptible to failure due to shear of the fastener post 25 oregging out of the hole in the cutter 10 because the mounting surface 40is non-parallel with the dominant force vector 60. Stated another way,the resultant impact force acting on the cutter 10 is in a directionthat is not perpendicular to the front edge 50, which generates a momenton the cutter 10 in a backward direction (relative to the direction oftravel). This moment tends to cause rotation of the cutter 10 relativeto the mounting bracket 20, which detrimentally increases the force onthe fastener post 25 and tends to dislodge the cutter 10 from thebracket 20. Also, due to the negative rake angle 75 (i.e. backwardrelative to the direction of travel), the cutter 10 has to be designedmore robustly directly behind the cutter edge 70 to resist failure.

Typically, existing cutter systems use robust fasteners to counteractthe shear forces encountered during operation. Many existing systemsinclude more than one fastener to secure the cutter onto a cutter wheel.In some cases, each of these fasteners can be up to 0.875 inches indiameter. Use of multiple, large fasteners undesirably increases thecost to manufacture the cutter and complicates the installation andremoval of the cutters from the wheel.

SUMMARY

The present invention overcomes the disadvantages of existing systems inseveral ways.

In a first aspect, the invention provides a cutter configured to bemounted on a rotationally driven apparatus for material reduction of anobject. The cutter includes a first end configured to first engage theobject along a dominant force vector, a second end opposite the firstend, a first side, and a second side opposite the first side. The cutterhas a length between the first end and the second end, and a widthbetween the first side and the second side. The cutter further includesan outer side, an inner side configured to engage the rotationallydriven apparatus, and an aperture extending from the outer side to theinner side along a fastener axis that is substantially perpendicular tothe dominant force vector. The aperture is configured to receive afastener to secure the cutter to the apparatus. The cutter also includesa cutter tip on the first end and having a first cutting edge extendingalong the first side, a second cutting edge extending along the secondside, and a third cutting edge extending along the outer side, thecutting edges defining therebetween a cutting face of the cutter tip.The cutting face is configured to define a cutting swath having a widthbetween the first cutting edge and the second cutting edge as the cutterrotates with the apparatus. No portion of the first side or the secondside extends outside the width of the cutting swath.

In a second aspect, the invention provides a cutter configured to bemounted on a rotationally driven apparatus for material reduction of anobject. The cutter includes a first end including a cutting tipconfigured to first engage the object along a dominant force vector, asecond end opposite the first end, a first side, and a second sideopposite the first side. The cutter has a length between the first endand the second end, and a width between the first side and the secondside. The cutter further includes an outer surface and an inner surfacehaving portions configured to engage the rotationally driven apparatus.The inner surface includes a mounting surface portion configured toengage a first surface of the apparatus and a plurality of reactionsurface portions configured to engage mating surfaces of the apparatusand disposed between the mounting surface portion and the first end. Atleast two of the plurality of reaction surface portions are angledrelative to one another such that the plurality of reaction surfaceportions extend along the width from the first side to the second sidein a non-planar manner. An aperture extends from the outer surface tothe mounting surface portion along a fastener axis that is substantiallyperpendicular to the mounting surface portion and to the dominant forcevector. The aperture is configured to receive a fastener to secure thecutter to the apparatus.

In another aspect, the invention provides a rotating cutting assemblyincluding a wheel configured to be mounted on a rotationally drivenapparatus for material reduction of an object and a cutter removablycoupled to a side surface of the wheel. The cutter includes a first endconfigured to first engage the object along a dominant force vector, asecond end opposite the first end, a first side, and a second sideopposite the first side. The cutter has a length between the first endand the second end and a width between the first side and the secondside. The cutter further includes an outer side, an inner sideconfigured to engage the wheel, and an aperture extending from the outerside to the inner side along a fastener axis that is substantiallyperpendicular to the dominant force vector. The aperture is configuredto receive a fastener to secure the cutter to the wheel. The cutter alsoincludes a cutter tip on the first end and having a first cutting edgeextending along the first side, a second cutting edge extending alongthe second side, and a third cutting edge extending along the outer sidesuch that the cutting edges define therebetween a cutting face of thecutter tip. The cutting face is configured to define a cutting swathhaving a width between the first cutting edge and the second cuttingedge as the cutter rotates with the apparatus. No portion of the firstside or the second side extends outside the width of the cutting swath.The wheel further includes a gullet formed therein and adjacent thecutter, and wherein the gullet includes a straight segment defining afirst leg of the gullet positioned adjacent the cutter tip, and anarcuate segment defining a second leg of the gullet.

BRIEF DESCRIPTION OF THE FIGURES

The foregoing and other features and advantages of the disclosure willbe apparent from the more particular description of the embodiments, asillustrated in the accompanying drawings, in which like referencecharacters refer to the same parts throughout the different figures. Thedrawings are not necessarily to scale, emphasis instead being placedupon illustrating the principles of the disclosure.

FIG. 1 illustrates an exemplary material reduction machine including asystem for integrated cutter mounting and wheel wear embodying aspectsof the present invention.

FIG. 2 is a perspective view of the cutter wheel of FIG. 1.

FIG. 3 is a front elevation view of the cutter wheel of FIG. 2, withrear, top, and bottom elevation views being similar.

FIG. 4 is a right elevation view of the cutter wheel of FIG. 2, with aleft elevation view being a mirror image thereof.

FIG. 5 shows the drive plate of FIG. 2 in further detail, inembodiments.

FIG. 6A is a perspective view of an exemplary cutter attached to thecutter wheel of FIG. 2.

FIG. 6B is a side view of the cutter of FIG. 6A.

FIG. 7 is a cross-section view of two cutters consistent with what isshown in FIGS. 6A, 6B that are symmetrically mounted together on thecutter wheel of FIG. 2 that includes a drive plate and wear platessandwiching the drive plate.

FIG. 8 is a cross-section view of two the cutters consistent with whatis shown in FIGS. 6A, 6B that are mounted offset on the cutter wheel ofFIG. 2 that includes the drive plate and wear plates.

FIG. 9 is a perspective view of another exemplary cutter wheel for usewith the machine of FIG. 1, including a plurality of cutters.

FIG. 10 is a right elevation view of the cutter wheel of FIG. 9.

FIG. 11 is a right elevation view of a drive plate of the cutter wheelof FIG. 9.

FIG. 12 is a right elevation view of one wear plate segment of thecutter wheel of FIG. 9, without the cutters attached to the cutterwheel.

FIG. 13 is a schematic representation of a profile of a contactinterface between an exemplary boss on the cutter of FIG. 9 and acomplementary recess.

FIG. 14 is a schematic representation of another profile of a contactinterface between an exemplary boss on the cutter of FIG. 9 and acomplementary recess.

FIG. 15 is a schematic representation of another profile of a contactinterface between exemplary bosses on the cutter of FIG. 9 andcomplementary recesses.

FIG. 16 is a schematic representation of another profile of a contactinterface between an exemplary boss on the cutter of FIG. 9 and acomplementary recess.

FIG. 17 is a perspective view of an exemplary cutter including a singlefastener mounting aperture and a single cylindrical boss offset from theaperture.

FIG. 18A is a perspective view of another exemplary cutter including asingle fastener aperture and a boss offset from the aperture.

FIG. 18B is an elevation view of the cutter of FIG. 18A, illustratingthe spacing between the aperture and the boss, and the profile of thecutter.

FIG. 18C is a bottom view of the cutter of FIG. 18A illustrating theaperture and the boss.

FIG. 18D is a perspective view of another exemplary cutter that issimilar to the cutter of FIG. 18A and including a single fasteneraperture and a boss offset from the aperture.

FIG. 19A is a perspective view of another exemplary cutter including asingle fastener aperture and a boss offset from the aperture.

FIG. 19B is a side view of the cutter of FIG. 19A.

FIG. 19C is a bottom view of the cutter of FIG. 19A illustrating theaperture and the boss.

FIG. 19D is a side elevation view of the cutter of FIG. 19A mounted ontoa plate having a complementary recess or pocket for the boss.

FIG. 20 is a perspective view of another exemplary cutter wheelincluding a drive plate, wear plates with wear plate segments, cutterteeth, and a plurality of drive plate wear prevention cutters.

FIG. 21 is a perspective view of an enlarged portion of the cutter wheelof FIG. 20 illustrating one of the drive plate wear prevention cutters.

FIG. 22 is a side elevation view of a portion of the cutter wheel ofFIG. 20.

FIG. 23 is a perspective view of another exemplary cutter wheelincluding a drive plate, wear plates with wear plate segments, cutterteeth, and a plurality of drive plate wear prevention cutters.

FIG. 24 is a right elevation view of one of the wear plate segments ofFIG. 23, including a mounting feature for receiving the drive plate wearprevention cutters.

FIG. 25 is a partial side elevation view of the cutter wheel of FIG. 23.

FIG. 26 is a perspective view of a portion of another exemplary cutterwheel including a wear prevention feature that may be used in any cutterwheel illustrated in FIGS. 1-25.

FIG. 27 is a side view of the cutter wheel of FIG. 26 with one of thewear plates removed to expose the drive plate.

FIG. 28 is a perspective view of an exemplary rotating drum for materialreduction, including a plurality of cutter assemblies mounted on thedrum.

FIG. 29 is a perspective view of one cutter assembly of FIG. 28,including a cutter mount, a cutter, a fastener, and a cutter fastenerinsert.

FIG. 30 is a perspective view of the cutter mount of FIG. 29.

FIG. 31 is a perspective view the cutter fastener insert of FIG. 29.

FIG. 32A is a perspective view of another exemplary cutter including asingle fastener aperture and a boss offset from the aperture.

FIG. 32B is a side view of the cutter of FIG. 32A.

FIG. 32C is a bottom view of the cutter of FIG. 32A illustrating theaperture and the boss.

FIG. 32D is a side elevation view of the cutter of FIG. 32A mounted ontoa plate having a complementary recess or pocket for the boss.

FIG. 33A is a section view of a portion of a cutter wheel illustrating adominant force vector acting on an exemplary cutter.

FIG. 33B is a schematic view of a cutter wheel illustrating a dominantforce vector acting on an exemplary cutter.

FIG. 33C is a schematic view of another cutter wheel illustrating adominant force vector acting on exemplary cutters.

FIG. 34 is a perspective view of another exemplary cutter wheel.

FIG. 35 is a partial section view taken through an aligned pair ofcutters on the wheel of FIG. 34.

FIG. 36 is a perspective view of another exemplary cutter wheel

FIG. 37 is a side view of the cutter wheel of FIG. 36, shown with onecutter removed.

FIG. 38 is a side view of the cutter wheel of FIG. 36 shown with a wearplate section and several cutters removed.

FIG. 39 is an exploded view of a cutter mount of the cutter wheel ofFIG. 36

FIG. 40 is a front view of the cutter shown on the cutter wheel of FIG.36.

FIG. 41 is a side view of the cutter of FIG. 40.

FIG. 42 is a perspective view of the cutter of FIG. 40.

FIG. 43 is an exploded perspective view of the cutter of FIG. 42.

FIG. 44 is a bottom perspective view of the cutter of FIG. 40.

FIG. 45 is a bottom view of the cutter of FIG. 40.

FIG. 46 is a side elevation view of the cutter of FIG. 40 mounted onto aplate having a complementary boss-receiving feature.

FIG. 47 is partial top view of cutters mounted to the cutter wheel ofFIG. 36.

FIG. 48 is a partial perspective view of two mounted cutters on thecutter wheel of of FIG. 36.

FIG. 49 is an end view of the cutter wheel of FIG. 36 schematicallyillustrating the cutter coverage pattern during revolution of the cutterwheel.

FIG. 50 is an enlarged end view of the cutter coverage pattern of FIG.49.

FIG. 51 is a perspective view of another exemplary cutter wheel

FIG. 52 is a side view of the cutter wheel of FIG. 50, shown with twocutters removed.

FIG. 53 is a section view through a mounted pair of cutters on thecutter wheel of FIG. 50.

FIG. 54A is an exploded perspective view of a prior art cutter assemblyincluding a mounting bracket and a cutter.

FIG. 54B is a schematic view of the cutter of FIG. 54A mounted onto acutter drum.

FIG. 54C is an enlarged schematic view of the cutter of FIG. 54A on thecutter drum.

FIG. 54D is a further enlarged schematic view of the cutter of FIG. 54Aillustrating the mounting arrangement relative to a plane and a dominantforce vector.

DETAILED DESCRIPTION

The embodiments herein provide a means of distributing cutter tooth(e.g. stump cutter tooth) loading through an intermediate (wear) plateattached to a cutter wheel instead of through shear of a fastenercoupling the cutter tooth to the cutter wheel. Prior designs show twofasteners of one cutter tooth sharing the cutter tooth's load whichfrequently creates excessive shear forces on the fasteners, causingfailure or reduced life. Moreover, prior designs that use cuttersembedded into recesses within the cutter wheel itself suffer fromdisadvantages of high manufacturing cost and additional cutter wheelwear that leads to replacement of an entire cutter wheel, which can becostly. For example, the interaction between the cutter and the cutterwheel cause the aperture in the cutter wheel to obtain wear and becomemisshapen, thereby requiring repair or replacement of the cutter wheel.

The present embodiments herein disclose a cutter wheel design such thatcutter tooth loads are transferred to a drive plate through anintermediate mounting plate and/or a boss on the cutter tooth. Allfasteners that pass through the intermediate mounting plate share theload and have minimal to no shear force exerted on the fastener itself.The intermediate mounting plate also serves as a replaceable wear plate.The embodiments described herein are significantly advantageous overcutter teeth mounted to a wheel in a co-planar fashion, like thosedescribed in the Background.

FIG. 1 depicts a material reduction machine 100. The material reductionmachine 100 includes a mainframe 102 and a cutter system 104 attachedthereto. The mainframe 102 is a vehicle including a cab 106, an enginecompartment 108, and a track 110. An operator sits within the cab 106 tocontrol operation of the material reduction machine 100. The enginecompartment 108 houses an engine for powering the material reductionmachine 100. The track 110 maneuvers the material reduction machine 100across a working terrain. It should be appreciated that mainframe 102need not be a vehicle as shown, but instead could be a walk-behindmainframe, such as that shown in FIG. 1 of U.S. patent application Ser.No. 14/147,277, filed Jan. 3, 2014 by Vermeer Manufacturing Company andentitled “Stump Cutter Disc With Recessed Tooth Pockets”.

The cutter system 104 is coupled to the mainframe 102 via a sub-frame112. The sub-frame 112 is configured to raise and lower a cutter wheel114 relative to the mainframe 102, such as along axis 101 within FIG. 1.The sub-frame 112 is further configured to swing the cutter wheel 114left and right relative to the mainframe 102, such as along axis 103within FIG. 1. It should be appreciated that the axis 101 and the axis103 need not be entirely perpendicular to one another, or perpendicularto the mainframe. In other words, the cutter wheel 114 may move closerand further away from the mainframe 102 when either raising, lowering,swinging left, or swinging right, such as in an arcuate motion. Thesub-frame 112 may further support a drive system 116 that powers androtates the cutter wheel 114. The drive system 116 may include adriveshaft at the axis of rotation A of the cutter wheel 114 andassociated drive system components for rotating the driveshaft andthereby rotating the cutter wheel, and controls that are operable by theoperator within the cab 106 of the material reduction machine 100.

Referring to FIGS. 2-5, the cutter wheel 114 includes a drive plate 202,and at least one wear plate 204 located on each side or face of thedrive plate 202. In FIGS. 2-4, a first wear plate 204(1) and a secondwear plate 204(2) are shown. It should be appreciated that there may beonly a single wear plate 204 located on one side of the drive plate 202.

The drive plate 202 may have a mass, or mass moment of inertia,specifically designed to provide enough potential energy to power thecutters 216, 220 (described below) through the initial engagement withthe wood or material being reduced. The illustrated drive plate 202 is asingle plate which is formed from a single material (such as grade 50steel, steel having a minimum yield of 50,000 PSI, abrasion-resistantmaterial, hard-faced material, or similar material). In alternativeembodiments, the drive plate 202 may include a plurality of drive plates(each being of a single material) adhered, bonded, welded, or positionedadjacent to one another. Similarly, each wear plate 204 may include aplurality of wear plates that are adhered, bonded, welded, or positionedadjacent to one another.

The drive plate 202 is configured to couple to the drive system 116. Forexample, the drive plate 202 includes a driveshaft aperture 206 and aplurality of driveshaft mounting apertures 208 each of which areconfigured such that driving torque is transferred from the drive system116 to the cutter wheel 114. In other embodiments, the driveshaft may bea stub shaft which only attaches to one side of the drive plate 202.

Each wear plate 204 includes an inner driveshaft mounting apertureconfigured to allow the drive system 116 to connect to the drive plate202 without connecting to each wear plate 204. In other embodiments,each wear plate 204 may entirely cover the drive plate 202. Each wearplate 204 may have a diameter or outer dimension that is the same orgreater than the diameter or outer dimension of the drive plate 202. Theembodiments in which the wear plate 204 has an outer dimension that islarger than the outer dimension of the drive plate 202 provide theadvantage that the wear plate 204 protects the circumference of thedrive plate 202 from wear during operation of the material reductionmachine 100. The profile of the cutter wheel 114 is not limited to acircular profile shape, such as that shown in the embodiments of FIGS.2-5. Instead the profile of the cutter wheel 114 may be any shapedesired, such as generally an oval, star, polygonal shape, helicalshape, combination thereof, or other arbitrary shape. One suchadditional profile shape is shown in FIGS. 9-12, discussed below.

A disadvantage of current cutter technology is wear on the wheel. Wheelsare generally made of a moderately wear resistant material (e.g., T1)and are often covered in hard facing. In high use, wear from landclearing operations may be so significant that frequent repairs to thewheel still need to be made. Embodiments herein, including thosedescribed below, provide the advantage that the drive plate 202 may bemanufactured using a first material that has a first wear resistance,and the wear plates 204 may be manufactured using a second material thathas a second wear resistance greater than the first wear resistance. Inan example, the first material may be grade 50 steel, and the secondmaterial may be high carbon abrasion resistant steel. The material ofthe drive plate 202 may have a lower carbon content than the material ofthe wear plates 204. This lower carbon content of the drive plate 202facilitates machinability of the drive plate 202, and also, in someembodiments, facilitates welding cutters or cutter mounts to the outerperiphery of the drive plate 202.

Each wear plate 204 has a thickness that may be equal or unequalrelative to the thickness of the drive plate 202. In some embodiments,each wear plate 204 has a thickness that is less than a thickness of thedrive plate 202. These embodiments provide the advantage of easier andlower cost manufacturing. A material's wear resistance typically affectsthe manufacturability of items using the material. A multi-layeredcutter wheel, such as that shown in FIGS. 1-4 allows for the drive plate202 to be manufactured having an equal or greater thickness than thewear plates 204. The drive plate 202, being of a less-wear-resistantmaterial (although the drive plate 202 may have the same wear-resistanceas the wear plate 204) is more easily manufactured (because of reducedthickness and/or reduced wear resistance) and may be manufactured usingless costly manufacturing techniques. The wear plates 204 are easier tomanufacture because the wear plates 204 are thinner than the drive plate202 when compared to manufacturing an entire cutter wheel of similarwear-resistant material. Therefore, the present invention provides theadvantages of easier manufacturing and lower cost.

In some embodiments, each wear plate 204 can be a single plate. However,in the illustrated embodiments, one or more of the wear plates 204 mayinclude a plurality of wear plate segments 210 that collectively formthe wear plate 204. For example, wear plates 204(1), 204(2) include fourwear plate segments 210(1)-210(4). It should be appreciated that theremay be more or fewer wear plate segments without departing from thescope hereof. Embodiments including wear plate segments provide theadvantage that a wear plate segment is lighter than a single,all-encompassing wear plate. As such, a single operator may replace thewear plate because the operator is able to lift the wear plate segment.Another advantage is that replacing a wear plate segment does notrequire removal of the drive plate from the shaft. In embodiments, thewear plate segments 210 that collectively form a wear plate 204 may bestatically and dynamically balanced. Thus, the operator may replace anentire set of wear plates 210 (e.g. all wear plate segments 210 thatcollectively form a single wear plate 204) and maintain balance of thecutter wheel 114.

The illustrated wear plates 204 and/or wear plate segments 210(1)-210(4)are shown as being planar parts without bends, projections, or otherfeatures deviating from the plane. This facilitates manufacturing andassembly. Furthermore, in each of the embodiments illustrated herein,the wear plates or wear plate segments operate to cover a majority(i.e., more than half) of the surface area of the side of the driveplate. In some embodiments, at least seventy-five percent of the surfacearea of the side of the drive plate is covered by the wear plate or wearplate segments. In yet other embodiments, at least eighty-five percentof the surface area of the side of the drive plate is covered by thewear plate or wear plate segments. In other embodiments, at leastninety-five percent of the surface area of the side of the drive plateis covered by the wear plate or wear plate segments. In the illustratedembodiments, the wear plates or wear plate segments extend over allportions of the side of the drive plate where cutters are mounted.

Each wear plate segment 210 includes a leading edge and a trailing edgethat is defined relative to the direction of rotation of the cutterwheel during operation. When mounted, the leading edge of one wear platesegment is generally aligned with the trailing edge of the adjacent wearplate segment such that the leading edge and the trailing edge of theadjacent wear plate segments define a joint. For purposes of descriptionand the claims, the joint can interchangeably be referred to by eitherthe trailing edge or the leading edge of the adjacent wear platesegments. The joint (e.g., the leading edge of one wear plate segment orthe trailing edge of the adjacent wear plate segment) may extendradially (i.e. along an axis or plane extending through the rotationalcenter of the cutter wheel). In some embodiments, the joint may beangled forward or backward relative to the direction of rotation. Forexample, as shown in FIG. 4, each wear plate segment 210 includes aleading edge 402 and a trailing edge 404 that define a joint that isangled in a direction that is backward relative to the direction ofrotation of the cutter wheel 114 during operation (i.e. during rotationof the cutter wheel 114 in the direction shown by arrow 401). Theleading edge 402 and trailing edge 404 are only labeled in FIG. 4relative to wear segment 210(1) for simplicity in understanding thefigure. However, it should be appreciated that each of the wear platesegments 210(1)-210(4) includes a leading and trailing edge 402, 404.The backward angle of the leading and trailing edges 402, 404 providesthe advantage that material will not be driven inward by continuedrotation and thus catch on the edge of each wear plate segment 210during operation.

In certain embodiments, each of the wear plate segments 210 has the sameprofile (i.e. shape). However, in some embodiments, the wear platesegments 210 may have different shapes from one another that arecoordinated to form the wear plate 204 and thus may accommodate uniquecutter patterns. For example, as shown in FIG. 4, wear plates 210(1) and210(3) have a first shape, and wear plates 210(2) and 210(4) have asecond shape. Each of the first and second shapes is alternating withinthe wear plate 204. The first shape includes a leading edge 402 that hasa first angled edge portion 406 and a second angled edge portion 408that is different from and angled relative to the first angled edgeportion 406. The trailing edge 404 of the second shape has acomplementary first angled edge portion 410 and a second angled edgeportion 412 such that the first shape mates with the second shape.

The wear plate segments 210, or the entire wear plate 204 if there areno segments thereof, may be removable from the drive plate 202 withoutremoving the drive plate 202 from the drive system 116. Thisconfiguration provides easy maintenance, and/or replacement, of the wearplates 204 without having to take apart the entire cutter wheel 114.

In some embodiments, an alignment aperture 212 may extend through eachwear plate 204 and the drive plate 202 to facilitate aligning andmounting the wear plates 204 onto the drive plate 202. During assemblyof the cutter wheel 114, an alignment fastener (such as a bolt, screw,pin, etc.) may be inserted (e.g. press fit, or fastened with a nut,spring clip, etc.) within the alignment aperture 212. An alignmentfastener is shown located in each of alignment apertures 212(2)-212(4).In some embodiments, the alignment fastener is maintained within thealignment aperture 212 during operation of the cutter wheel 114. Inother embodiments, the alignment fastener is removed from the alignmentaperture 212 during operation of the cutter wheel 114. In embodimentsincluding multiple wear plate segments 210, each wear plate segment 210may include an alignment aperture 212 there through (and also throughthe drive plate 202).

A plurality of cutters 216 may be fastened or coupled to the cutterwheel 114 at a surface of the wear plate 204 that is opposite thesurface facing the drive plate 202. The cutters 216 may be fastened withone or more fasteners 218. It should be appreciated that although twofasteners are shown per cutter 216 in FIG. 4, there may be more or fewerfasteners per cutter without departing from the scope of the invention.The fastener 218 may create a clamping force between the cutter 216,each wear plate 204, and the drive plate 202 such that the wear plate204 is held in place relative to the drive plate 202 via frictionbetween the wear plate 204 and the drive plate 202. As such, the morecutters 216 that are coupled to the cutter wheel 214, the greater thefriction is between the drive plate 202 and the wear plate 204. Itshould be appreciated that all cutters 216 may be the same in someembodiments, or in certain embodiments, there may be a first type ofcutter (e.g. cutters 216) and a second type of cutter 220. The secondtype of cutter 220 may be located along the circumference of the cutterwheel 114, while the first type of cutter 216 is located on the outersurfaces of the cutter wheel 114. Not all cutters 216, 220 are labeledin FIGS. 2-4 for clarity. The cutters 216, 220 may be coupled to thecutter wheel 114 via the fastener 218 engaging the drive plate 202, insome embodiments such as shown in FIG. 8. In additional or alternativeembodiments such as shown in FIG. 7, the fasteners 218 couple pairs ofcutters 216, 220 together such that the fastener couples one cutter,located on a first side of the cutter wheel 114, to a second cutter 216located on a second side of the cutter wheel 114, thereby producing theclamping force to maintain the wear plate 204 in location relative tothe drive plate 202.

If the friction caused by the collective fasteners 218 is not sufficientto maintain the wear plate 204 in location relative to the drive plate202, there may be additional fasteners that fasten the wear plate 204 tothe drive plate 202. These additional fasteners can be located at thealignment apertures 212. It will be appreciated that the frictionbetween the wear plates 204 and the drive plate 202 caused by thefasteners 218 may be greater than the friction caused by the additionalfasteners located at the alignment apertures 212.

As shown in FIG. 4, the cutter wheel 114 can include maintenanceapertures 222(1)-222(4). Maintenance apertures 222 prevent rotation ofthe cutter wheel 114 during service (such as removing/installing cutters216, wear plates 204, or wear plate segments 210) via a pin or bar (oranother device component) that is inserted into the apertures 222. Thetightening of fasteners on the wheel 114 generally causes the cutterwheel 114 to rotate, which may be inconvenient and increase difficultyfor servicing the wheel 114. To avoid this, the cutter wheel 114 can berotated manually so the pin/bar/device component of the sub-frame 112can be engaged in one of the maintenance apertures 222 to preventrotation.

As shown in FIG. 5, the drive plate 202 is a single plate (i.e. it isnot segmented like embodiments of the wear plates 210 discussed above).The drive plate 202 includes the maintenance apertures 222(1)-222(4)therethrough, and a plurality of mounting apertures 502. The mountingapertures 502 may extend all the way through the drive plate 202,particularly where the fasteners 218 couple pairs of cutters 216 on eachside of the cutter wheel 114 together, thereby producing theabove-discussed clamping force. The mounting apertures 502 may extendpartially or all the way through the drive plate 202 and are threaded,particularly where the fasteners 218 couple to the drive plate 202directly, thereby producing the above discussed clamping force. Themounting apertures 502 may be oversized relative to the fastener 218 inembodiments where the fastener couples two of the cutters 216 togethersuch that shear force on the fastener 218 is reduced while tension forceon the fastener 218 is maintained. With the mounting apertures 502 beinglarger than the diameter of the fasteners 218, the fasteners 218 canextend through the drive plate 202 without contacting the drive plate202 (see FIG. 7).

FIG. 6A depicts a cutter 600 that is consistent with the presentinvention. The cutter 600 is an example of the cutter 216 of the system100. It should be appreciated that the cutters may have alternate shapesand configurations without departing from the scope hereof. Examples ofsuch different cutters will be described further below.

The cutter 600 includes an inner surface 602 and an outer surface 604opposite the inner surface 602. A cutter tip 606 extends from the outersurface 604. The cutter tip 606 may include a projection 608 and acutter wear pad 610. The cutter wear pad 610 may be separate from,integral with, or otherwise a removable attachment on the cutterprojection 608 (e.g., a carbide insert). The cutter tip 606 may beangled to provide a rake angle that is zero, positive, or negative (in aradial direction and/or an axial direction relative to the wheel and thedirection of travel). It should be appreciated that all cuttersdescribed herein may include a cutter tip similar to cutter tip 606.

The inner surface 602 is configured for location against the wear plate204 of the cutter wheel 114. In some embodiments, the inner surface 602abuts the wear plate 204 directly. In the illustrated embodiment, awasher or shim 701 (see FIG. 7) can be located between the outer surfaceof the wear plate 204 and the inner surface 602. The washer or shim 701ensures even clamp load in the event that the inner surface 602 hasirregularities. The washer or shim 701 may comprise a material that issofter than the cutter 600 and the wear plate 204 and is sandwichedbetween the two harder materials of the cutter 600 and the wear plate204.

The cutter 600 includes two bosses 612 extending outward from the innersurface 602. Although the cutter 600 is described in detail with twobosses 612, it will be appreciated that the cutter 600 can include asingle boss 612. The bosses 612 are configured to extend into a bossreceiving recess on the wear plate 204. Each illustrated boss 612 isconcentric around a cutter fastener-mounting aperture 614, although thebosses 612 may be offset from the fastener-mounting aperture 614. Forexample, the boss may be offset in a forward direction of rotation ofthe cutter wheel 114 when operating. In such offset embodiments, thefastener-mounting aperture 614 (and/or wear-plate mounting apertures702, 802 discussed below) may be oversized relative to the fastener 218such that shear force on the fastener 218 is reduced while tension forceof the fastener 218 is maintained.

In some embodiments, a single boss 612 may surround multiplefastener-mounting apertures 614. The boss 612 may be cylindrical asshown, or have other shapes (e.g., square, rectangular, or polygonal;see examples illustrated in FIGS. 13-19). The boss 612 may form theprofile of the inner surface 602 instead of taking the form of aprotrusion extending outward from the surface 602. The fastener-mountingaperture 614 is configured to be aligned with the mounting apertures 502in the drive plate 202 discussed relative to FIGS. 2-5.

FIG. 6B shows the effect of the dominant direction of cutting force(also referred to as the dominant force vector) on the configuration ofthe cutter 600. Cutter tip 606 is offset (in more than one plane) fromthe fastener mounting aperture(s) 614. This offset distance 616 createsa rotational force (moment 618) about an instantaneous center, inaddition to the translational force(s) and the resultant forces 620 atthe fastener-mounting aperture(s) that result from the moment 618.

FIG. 7 depicts a cross section view 700 of a pair of the cutters 600mounted together on the cutter wheel 114 of FIGS. 1-5, including thedrive plate 202 and two wear plates 204. View 700 illustrates a firstcutter 600(1) paired with a second cutter 600(2) on opposite sides ofthe cutter wheel 114. A first and second washer 701(1), 701(2) are shownlocated between the inner surface 602 and wear plate 204 of each cutter600(1), 600(2), respectively. FIG. 7 also depicts an example of thealignment apertures 212 with an alignment fastener located therein.

The first cutter 600(1) has first and second fastener-mounting apertures614(1), 614(2) that respectively align with the first and secondfastener-mounting apertures 614(3), 614(4) of the second cutter 600(2).A first fastener 218(1) extends from the first cutter 600(1) to thesecond cutter 600(2), within the fastener-mounting apertures 614(1) and614(3) and through the first drive plate mounting aperture 502(1), andfirst and third wear-plate mounting apertures 702(1), 702(3) within eachof the first and second wear plates 204(1), 204(2), respectively. Asecond fastener 218(2) extends from the first cutter 600(1) to thesecond cutter 600(2), within the fastener-mounting apertures 614(2) and614(4) and through the second drive plate mounting aperture 502(2), andthe second and fourth wear-plate mounting apertures 702(2) and 702(4)within each of the first and second wear plates 204(1), 204(2),respectively.

It should be appreciated that the first wear-plate mounting apertures702(1), 702(2) may have a first dimension or diameter D₁, the secondwear-plate mounting apertures 702(3), 702(4) may have a second dimensionor diameter D₂, and the drive plate mounting apertures 502(1), 502(2)may have a third dimension or diameter D₃. The first, second and thirddimensions may be circular (i.e. the dimension is a diameter) or anothershape (square, rectangular, etc.) such that the first, second and thirddimensions correspond to the width of the apertures 702(1), 702(2),702(3), 702(4), 502(1), 502(2). Dimensions D₁ and D₂ may be larger orsmaller than one another, and larger or smaller than dimension D₃.

The third and fourth fastener-mounting apertures 614(3), 614(4) of thesecond cutter 600(2) are threaded to cooperate with threads of thefasteners 218(1), 218(2). Thus, the fastener-mounting apertures 614(3),614(4) are also considered to be fastener-receiving apertures. The firstand second fastener-mounting apertures 614(1), 614(2) of the firstcutter 600(1) include a first sidewall 704, a second sidewall 706, and aflange 708. Accordingly, as the fasteners 218(1), 218(2) are tightened,a surface of fastener head 710 applies a force against the flange 708,and the threads of the fastener 218 act to clamp the two cutters 600(1),600(2) together, thereby creating a clamping action that operates tomaintain position of the wear plates 204 relative to the drive plate202. As such, the tightening of one or more of the fasteners 218 causesthe cutter 600(1) to clamp all components between the first cutter600(1) and the second cutter 600(2) and (e.g. the drive plate 202, thewear plate 204, and the washer 701 (if present)). Increasing the numberof cutter pairs that are used with the cutter wheel 114 increases thefriction or clamping force imparted between the wear plates 204 anddrive plate 202. Thus, in embodiments where pairs of cutters 600 (orother cutters discussed herein) are coupled together, one of the cuttersin the pair may include threaded fastener-mounting aperture(s) orfastener-receiving apertures, and the other may includefastener-mounting aperture(s) that accommodate the fastener shape (suchas the bolt head).

The thickness of each boss 612 of the first and second cutters 600(1),600(2) can be less than or equal to a thickness of the correspondingwear plate in which the boss 612 is inserted adjacent the wear-platemounting apertures 702. This thickness configuration prevents the bosses612 from interfering with the clamping action of the cutters 600 as thefasteners 218 are tightened.

In some embodiments, a first clearance is defined between a sidewall ofeach mounting aperture 502 and the fastener 218. A second clearance isdefined between the first sidewall 704(1), 704(2) and the fasteners218(1), 218(2), respectively. A third clearance is defined between thesecond sidewall 706(1), 706(2) the fastener-mounting apertures 614(1),614(2) and the fastener 218(1), 218(2). These clearances may be equal orunequal. One or more of the first, second, and third clearances(including but not limited to all three) is greater than or equal to afourth clearance defined between the bosses 612 and the respectivesidewall of the wear plate mounting aperture 702 of the wear plates 204.As such, the wear plate mounting aperture 702 forms a boss 612 receivingrecess that is sized and shaped with minimal to zero clearance aroundthe boss 612. This configuration allows the wear plates 204 to bear themajority, if not all of, the shear force caused by material contactingthe cutter tip 610 such that the shear force on the fastener 218 issubstantially reduced or eliminated.

FIG. 8 depicts a cross section view 800 of a pair of the cutters 600mounted offset on the cutter wheel 114 of FIGS. 1-5. The cutters 600(1)and 600(2) are offset from one another on each side of the cutter wheel114. The first cutter 600(1) has first and second fastener-mountingapertures 614(1), 614(2) that respectively align with the first andsecond drive plate mounting apertures 502(1), 502(2) of the drive plate202 and first and second wear plate mounting apertures 802(1), 802(2) inthe first wear plate 204(1). The first and second drive plate mountingapertures 502(1), 502(2) are threaded to cooperate with threads of thefasteners 218(1), 218(2).

The first wear-plate mounting apertures 802(1), 802(2) may have a firstdimension D₁, the second wear-plate mounting apertures 802(3), 802(4)may have a second dimension D₂, and the drive plate mounting apertures502(1), 502(2) may have a third dimension D₃. The first, second andthird dimensions may be circular (e.g. the dimension is a diameter), ormay be any arbitrary shape, such as square, rectangular etc. DimensionsD₁ and D₂ may be larger or smaller than one another, and larger orsmaller than dimension D₃.

The first and second fastener-mounting apertures 614(1), 614(2) of thefirst cutter 600(1) respectively include a first sidewall 804, a secondsidewall 806, and a flange 808. Accordingly, as the fasteners 218(1),218(2) are tightened, a surface of the fastener head applies a forceagainst the flange 808 to clamp the cutter 600(1) toward the drive plate202, which generates a clamping action that operates to maintainposition of the wear plate 204(1) relative to the drive plate 202. Assuch, tightening one or more of the fastener 218 causes the cutter 600to clamp all components between 600 and 202 (e.g. the wear plate 204 anda washer (if present)). Increasing the quantity of cutters 600 increasesthe friction or clamping force caused between the wear plate 204(1) anddrive plate 202.

In the illustrated embodiment, a thickness of the each boss 612(1),612(2) of the first cutter 600(1) is less than or equal to a thicknessof the wear plate 204(1) adjacent the wear-plate mounting apertures802(1), 802(2). This thickness configuration prevents the bosses 612from interfering with the clamping action of the cutters 600 as thefasteners 218 are tightened.

In the illustrated embodiment, a clearance between one or more of (a)the first sidewall 804 of the fastener-mounting apertures 614 and thefastener 218, and (b) the sidewall 806 of the fastener-mountingapertures 614 and the fastener 218 is greater than or equal to aclearance between the bosses 612 and the respective sidewall of the wearplate mounting aperture 802 of the wear plate 204(1). As such, the wearplate mounting aperture 802 forms a boss 612 receiving recess that issized and shaped with minimal to no clearance around the boss 612. Thisconfiguration allows the wear plates 204(1) to bear the majority, if notall of, the shear force caused by material contacting the cutter tip610, such that the shear force on the fastener 218 is eliminated orsubstantially reduced.

The second cutter 600(2) has third and fourth fastener-mountingapertures 614(3), 614(4) that respectively align with the third andfourth drive plate mounting apertures 502(3), 502(4) of the drive plate202 and third and fourth wear plate mounting apertures 802(3), 802(4) inthe second wear plate 204(2). The third and fourth drive plate mountingapertures 502(3), 502(4) are threaded to cooperate with threads of thefasteners 218(3), 218(4).

The third and fourth fastener-mounting apertures 614(3), 614(4) of thesecond cutter 600(2) respectively include a first sidewall 804, a secondsidewall 806, and a flange 808. Accordingly, as the fasteners 218(3),218(4) are tightened, a surface of the fastener head applies a forceagainst the flange 808 to clamp the second cutter 600(2) against thedrive plate 202 thereby creating a clamping action that operates tomaintain position of the wear plate 204(2) relative to the drive plate202. The more cutters located adjacent the wear plate 204(2), thegreater the friction or clamping force caused between the wear plate204(2) and drive plate 202.

In the illustrated embodiment, a thickness of the each boss 612(3),612(4) of the second cutter 600(2) is less than or equal to a thicknessof the wear plate 204(2) adjacent the wear-plate mounting apertures802(3), 802(4). This thickness configuration prevents the bosses 612from interfering with the clamping action of the cutter 600 as thefasteners 218 are tightened.

In the illustrated embodiment, a clearance between one or more of (a)the first sidewall 804 of the fastener-mounting apertures 614 and thefastener 218, and (b) the sidewall 806 of the fastener-mountingapertures 614 and the fastener 218 is greater than or equal to aclearance between the bosses 612 and the respective sidewall of the wearplate mounting aperture 802 of the wear plate 204(2). As such, the wearplate mounting aperture 802 forms a boss 612 receiving recess that issized and shaped with minimal to no clearance around the boss 612. Thisconfiguration allows the wear plate 204(2) to bear the majority, if notall of, the shear force caused by material contacting the cutter tip610, such that the shear force on the fastener 218 is substantiallyreduced or eliminated.

The embodiments described with regard to FIGS. 2-8 include bosses thatare concentric to the fastener-mounting aperture of the cutter, andboss-receiving recesses that are integral with the mounting apertures ofthe wear plates 204. It will be appreciated that the bosses may beoffset from the fastener mounting aperture 614 of the cutter 600, andthe boss receiving recess may be offset from the mounting aperture (e.g.mounting apertures 702, 802) within the wear plates 204.

FIGS. 9 and 10 illustrate another exemplary cutter wheel 900 that can beused in place of the wheel 114. The cutter wheel 900 is similar to thecutter wheel 114 described and illustrated with regard to FIGS. 2-5, andmay include any of the features of cutter wheel 114. As shown, thecutter wheel 900 has a non-circular profile (shape).

With reference to FIGS. 9-12, the cutter wheel 900 includes a driveplate 902 and wear plates 904(1), 904(2) that are located on each sideor face of the drive plate 902. It should be appreciated that there maybe only a single wear plate 904 located on one side of the drive plate902. The drive plate 902 may have a mass or mass moment of inertia thatis specifically designed to provide enough potential energy to powercutters 916, 920 through initial engagement with the wood or materialbeing reduced. The illustrated drive plate 902 (see FIG. 11) is a singleplate that is formed from a single material (e.g., grade 50 steel, steelhaving a minimum yield of 50,000 PSI, abrasion-resistant material,hard-faced material, or similar material). In some embodiments, thedrive plate 902 may be formed from multiple plates (e.g., each being aplate of a single material) that are adhered, bonded, welded, orpositioned adjacent to one another. Similarly, each wear plate 904 mayinclude a plurality of wear plates that are adhered, bonded, welded, orpositioned adjacent to one another.

The drive plate 902 is configured to couple to a drive system (e.g. thedrive system 116). The drive plate 902 includes a driveshaft aperture906 and a plurality of driveshaft mounting apertures 908 (not all ofwhich are labeled) so that driving torque from the drive system istransferred to the cutter wheel 900. In other embodiments, thedriveshaft may be a stub shaft which only attaches to one side of thedrive plate 902.

Each wear plate 904 includes an inner driveshaft mounting aperture thatallows the drive system 116 to connect to the drive plate 902 withoutconnecting to each wear plate 904. Each wear plate 904 may entirelycover the drive plate 902, or only a portion of the drive plate 902(leaving part of the drive plate 902 exposed). In some embodiments, eachwear plate 904 has a dimension that is equal to or greater than thecorresponding dimension of the drive plate 902. In other words, eachwear plate 904 has a profile, when viewed from one of the sides of thecutter wheel 900 that is larger than the profile of the drive plate 902.It should be appreciated, however, that the profile of each wear plate904 may be equal to the profile of the drive plate 902 without departingfrom the scope hereof. These embodiments provide the advantage that thewear plate 904 protects the outer edge of the drive plate 902 from wearduring operation of the material reduction machine (e.g. the materialreduction machine 100).

The drive plate 902 may be manufactured using a first material that hasa first wear resistance, and the wear plates 904 may be manufacturedusing a second material that has a second wear resistance greater thanthe first wear resistance. In an example, the first material may begrade 50 steel, and the second material may be high carbon abrasionresistant steel. The material of the drive plate 902 may have a lowercarbon content than the material of the wear plates 904. This lowercarbon content of the drive plate 902 facilitates machinability of thedrive plate 902, and also, in some embodiments, facilitates weldingcutters or cutter mounts to the outer periphery of the drive plate 902.

In some embodiments, each wear plate 904 has a thickness that is equalto the thickness of the drive plate 902. However, in other embodiments,each wear plate 904 has a thickness that is less than a thickness of thedrive plate 902. These embodiments provide the advantage of easier andlower cost manufacturing. A material's wear resistance typically affectsthe manufacturability of items using the material. A multi-layeredcutter wheel, such as that shown in FIGS. 9-12, allows for the driveplate 902 to be manufactured having an equal to or greater thicknessthan the wear plates 904. The drive plate 902, being of aless-wear-resistant material (although the drive plate 902 may the samewear-resistance as the wear plate 904) is more easily manufactured(because of reduced thickness and/or reduced wear resistance) and may bemanufactured using less costly manufacturing techniques. The wear plates904, because they are less thick than the drive plate 902 and/or ascompared to manufacturing an entire cutter wheel of similarwear-resistant material, are easier to manufacture. Therefore, thepresent embodiments provide the advantage of easier manufacturing andlower cost.

Each wear plate 904 can be a single plate, or can include wear platesegments 910 that collectively form the wear plate 904. For example,wear plates 904(1), 904(2) include three wear plate segments910(1)-910(3). It should be appreciated that there may be more or fewerwear plate segments without departing from the scope hereof. Embodimentsincluding wear plate segments provide the advantage that that a wearplate segment is lighter than an entire wear plate. As such, a singleoperator may replace the wear plate because the operator is able to liftthe wear plate segment. Another advantage is that replacing a wear platesegment does not require removal of the drive plate from the shaft. Inembodiments, the wear plate segments 910 that collectively form a wearplate 904 may be statically and dynamically balanced. Thus, the operatormay replace an entire set of wear plates 910 (e.g. all wear platesegments 910 that collectively form a single wear plate 904) andmaintain balance of the cutter wheel 900.

Each wear plate may include a leading edge and a trailing edge relativeto the angle of rotation of the cutter wheel during operation. Thisleading edge may be parallel to the normal angle the rotation of thecutter wheel, or may be angled forward or backward relative to therotation of the cutter wheel. In the illustrated embodiment shown inFIG. 12, each wear plate segment 910 includes a leading edge 1202 and atrailing edge 1204. Leading edge 1202 is angled backward relative to therotation of the cutter wheel 900 during operation (i.e. during rotationof the cutter wheel 900), such as along arrow 1001 in FIG. 10. It shouldbe appreciated that the leading edge 1202 may be modified to angleforward without departing from the scope hereof. The trailing edge 1204is also angled backward relative to rotation of the cutter wheel 900during operation. The leading edge 1202 and trailing edge 1204 is onlylabeled in FIG. 12 relative to wear segment 910(1) for simplicity ofillustration, however it should be appreciated that each of the wearplate segments 910(1)-910(3) include a leading and trailing edge 1202,1204.

In certain embodiments, each of the wear plate segments 910 has the sameprofile (i.e. shape). However, in some embodiments, the wear platesegments 910 may have different shapes from one another that arecoordinated to form the wear plate 904.

The wear plate segments 910, or the entire wear plate 904 if there areno segments thereof, may be removable from the drive plate 902 withoutremoving the drive plate 902 from the drive system (e.g. drive system116). This configuration provides easy maintenance of the wear plates904 without having to disassemble the entire cutter wheel 900.

In the illustrated embodiment, an alignment aperture 912 extends througheach wear plate 904 and the drive plate 902. Alignment apertures 912 aresimilar to the alignment apertures 212 discussed above. Accordingly, thediscussion of alignment apertures 212 applies to alignment apertures 912as well.

A plurality of cutters 916 may be fastened or coupled to the cutterwheel 900 at an opposite surface of the wear plate 904 from the driveplate 902. The cutters 916 may be fastened with at least one fastener918. Not all cutters 916 and fasteners 918 are labeled for simplicity ofillustration. It should be appreciated that although one fastener 918 isshown per cutter 916, there may be more fasteners per cutter withoutdeparting from the scope hereof. The fastener 918 may create a clampingforce between the cutter 916, each wear plate 904, and the drive plate902 such that the wear plate 904 is held in place relative to the driveplate 902 via friction and the clamping force between the wear plate 904and the drive plate 902. Increasing the quantity of cutters 916 that arecoupled to the cutter wheel 914 increases the clamping force between thedrive plate 902 and the wear plate 904. It should be appreciated thatall cutters 916 may be the same, or be different types of cutters. Somecutters may be offset along the axis of the driveshaft relative toothers of the cutters. For example, as shown in FIG. 9, cutters 920 aremounted to a cutter mount 921 such that the cutters 920 are offset fromthe cutters 916 along the axis of the driveshaft. In other embodiments,the cutters 920 may be mounted directly to the drive plate 902 withoutthe cutter mount 921 (and/or the cutter mount 921 may be integral withthe drive plate 902). Cutters 920 are outer-edge cutters in that theyare mounted on the outer-edge of the cutter wheel 900. Moreover, cutters920 are rotated along their longitudinal axis relative to thelongitudinal axis of the cutters 916 such that the cutter tip 925 of thecutters 920 extends from the cutter 920 away from an edge of the cutterwheel 900, as opposed to cutters 916 where the cutter tip thereofextends from a side surface of the cutter wheel 900.

The cutters 916 may be coupled to the cutter wheel 900 via the fastener918 engaging the drive plate 902 (similar to that shown in FIG. 8),although the fasteners 918 may instead couple pairs of cutters 916together such that the fastener 218 couples one cutter, located on afirst side of the cutter wheel 900, to a second cutter 916 located on asecond side of the cutter wheel 900 (similar to that shown in FIG. 7).In some embodiments where the clamping force imparted by the fasteners918 is not sufficient to maintain the wear plate 904 in locationrelative to the drive plate 902, there may be additional fasteners thatfasten the wear plate 904 to the drive plate 902. In these embodiments,these additional fasteners are located at the alignment apertures 912.The friction or clamping force between the wear plates 904 and the driveplate 902 caused by the fasteners 918 may be greater than the frictionor clamping force caused by the additional fasteners located at thealignment apertures 912.

The illustrated embodiment also includes maintenance apertures 922.Maintenance apertures 922 are for preventing rotation of the cutterwheel 900 during service—such as removing/installing cutters 916 and/orwear plates 904, and/or wear plate segments 910. The tightening offasteners causes the cutter wheel 900 to rotate which may beinconvenient and increase difficultly for a serviceman. To avoid this,the cutter wheel 900 can be rotated manually so a pin/bar/devicecomponent of the sub-frame 112 can be engaged in one of the maintenanceapertures 922 to prevent rotation.

As shown in FIG. 11, the drive plate 902 is a single plate (i.e. it isnot segmented like embodiments of the wear plates 910 discussed above).The drive plate 902 includes the maintenance aperture 922 therethrough,and a plurality of mounting apertures 1102 (not all of which are labeledfor clarity of illustration). In some embodiments, the mountingapertures 1102 may extend all the way through the drive plate 902,particularly where the fasteners 918 couple pairs of cutters 916 on eachside of the cutter wheel 900 together such as in the manner shown inFIG. 7, thereby producing the above discussed clamping force. Themounting apertures 1102 may extend partially or all the way through thedrive plate 902 and are threaded, particularly where the fasteners 918couple to the drive plate 902 directly such as in the manner shown inFIG. 8, to produce the clamping force. The mounting apertures 1102 maybe oversized relative to the fastener 918 in embodiments where thefastener couples two of the cutters 916 together such that shear forceon the fastener 918 is reduced while tension force on the fastener 918is maintained. With the mounting apertures 1102 being larger than thediameter of the fasteners 918, the fasteners 918 can extend through thedrive plate 902 without contacting the drive plate 902 (such as in themanner shown in FIG. 7).

The cutter wheel 900 may include a plurality of chip evacuation notchesor gullets 1002 on the perimeter of the cutter wheel 900 that extendthrough each of the drive plate 902 and each wear plate 904. The chipevacuation notches or gullets 1002 may also comprise apertures forwardlyadjacent to the inner cutters 916 without departing from the scopehereof. The chip evacuation notches 1002 allow material that is cut bythe cutters 916, 920, to evacuate through the chip evacuation notches1002 and release on the other side of the wheel 900 as the cutter wheel900 is traversing the material. The chip evacuation notches 1002 alsoreduce the recirculation of material during operation of the cutterwheel 900. The material can include material that has been cut by thecutters 916, 920. There is shown a single cutter 916 located adjacenteach chip evacuation notch 1002. However, it should be appreciated thatthere may be more cutters 916 adjacent each chip evacuation notch 1002without departing from the scope hereof. Moreover, although the chipevacuation notches 1002 are shown relative to the embodiment of FIGS.9-12, it should be appreciated that any embodiment discussed herein mayinclude the chip evacuation notch without departing from the scopehereof.

As shown in FIG. 12, each wear plate 904 includes, at the location ofeach cutter 916, a wear plate mounting aperture 1203 and a bossreceiving recess 1206 to receive a corresponding fastener and a boss onthe cutter 916, respectively. In general, the quantity of apertures 1203and recesses 1206 correspond to the quantity of fasteners being used tosecure each cutter 916 to the wear plate 904 and the quantity of bosseson the cutter 916. The wear plate mounting aperture 1203 may be similarto any of the wear plate mounting apertures discussed herein, such aswear plate mounting apertures 702, 802 discussed above. In someembodiments, the wear plate mounting aperture 1203 does not include aboss receiving recess concentric or at the same location thereof.

With continued reference to FIG. 12, the boss receiving recess 1206 maybe an aperture that extends entirely through, or partially through, thewear plate 904. The boss receiving recess 1206 may be entirelysurrounded by material of the wear plate 904, or may be a partialaperture, shoulder, or lip in or at an edge of the wear plate 904. Forexample, the boss receiving recess may be a boss receiving feature 1208that is located on a perimeter (e.g. a surface profile of the wear plate904) of the cutter wheel 900, such as at the location of the chipevacuation notches 1002. The boss receiving recess 1206 (and the bossreceiving feature 1208) includes a contact surface where clearancebetween the cutter boss and wear plate is minimal to no clearance. Thiscontact surface is opposite the boss in the direction of the prevailingforce applied by the cutter tooth, and provides a contact interface thatis the location where minimal to no clearance between the cutter bossand wear plate is desired.

FIGS. 13-16 illustrate exemplary profiles of the contact interfacebetween differently-shaped bosses and corresponding boss receivingrecesses, as well as a prevailing force (F) when the cutter wheel is inoperation. This force shown in these Figures is not representative ofall forces present on the cutter. The cutter may receive forces frommany directions, such as those shown in dashed arrows in FIGS. 13-16,and various transfer interfaces between a cutter profile and acorresponding receiving recess may be configured to aid in transferringforces from one or more directions. The forces that the cutterexperiences include, but are not limited to, radial forces (inward andoutward) relative to the axis of cutter wheel rotation. The bossreceiving feature (entirely surrounded by material of the wear plate oronly partially) works with the boss to counteract these forces.Accordingly, the boss may include one or more contact surfaces (e.g.,one or more reaction surfaces) that interact with sidewall(s) of theboss receiving recess to prevent rotation of the cutter, as well as totransfer forces to the wear plates.

FIG. 13 schematically illustrates a boss 1302 that has a square (orrectangle) shape, and a boss receiving recess 1304 with a correspondingshape that receives the square (or rectangle) shape. As shown, the boss1302 has a planar reaction surface 1310 that is configured to engage orcontact a planar sidewall 1314 of the recess 1304 at a force-transferinterface 1306. It will be appreciated that the force-transfer interfaceis defined by the reaction surface 1310 of the boss 1302 and thesidewall 1314 of the boss receiving recess 1304, and that the reactionforce is in a direction that is opposite the direction the force F. Theclearance at the force-transfer interface 1306 when force F is notapplied (e.g. when the cutter wheel is not in operation) is small (orzero) such that the force F is transferred to the wear plate via contactof the boss 1302 with the boss receiving recess 1304.

FIG. 14 schematically illustrates a boss 1402 that has a polygonal shapewith a portion that extends in the same direction as the prevailingforce on the cutter when the cutter wheel is in operation. It will beappreciated that the boss 1402 can instead or in addition have a portionthat extends in a direction against the prevailing force. A bossreceiving recess 1404 is shaped to receive the boss 1402. As shown, theboss 1402 has a non-planar reaction surface 1410 that has a plurality ofcontact surface sections 1412 (two of the four sections are labeled forpurposes of clarity) that are configured to engage or contact anon-planar sidewall 1414 of the recess 1404 at a force-transferinterface 1406. It will be appreciated that the force-transfer interface1406 is defined by the reaction surface 1410 of the boss 1402 and thesidewall 1414 of the boss receiving recess 1404, and that the reactionforce is in a direction that is opposite the direction the force F. Theclearance at the force-transfer interface 1406 when force F is notapplied (e.g. when the cutter wheel is not in operation) is small (orzero) such that the force F is transferred to the wear plate via contactof the boss 1402 with the boss receiving recess 1404.

FIG. 15 schematically illustrates two bosses 1502(1), 1502(2) that havea cylindrical shape (i.e. circular in cross-section). The boss profileshown in FIG. 15 is an example of the cutter 600. Each boss receivingrecess 1504(1), 1504(2) has a corresponding shape that receives thecircular shape. As shown, each boss 1502(1), 1502(2) has a non-planarreaction surface 1510(1), 1510(2), respectively that is configured toengage or contact a sidewall 1514(1), 1514(2), respectively of therecesses 1504(1), 1504(2) at force-transfer interfaces 1506(1), 1506(2).It will be appreciated that each force-transfer interface 1506(1),1506(2) is defined by the reaction surface 1510 of the boss 1502 and thecorresponding sidewall 1514 of the boss receiving recess 1504, and thatthe reaction force is in a direction that is opposite the direction theforce F. The clearance at the force-transfer interface 1506(1), 1506(2)when force F is not applied (e.g. when the cutter wheel is not inoperation) is small (or zero) such that the force F is transferred tothe wear plate via contact of the bosses 1502 with the boss receivingrecess 1504.

FIG. 16 schematically illustrates a boss 1602 that has a polygonal shapewith a recessed portion that extends in a direction opposite thedirection of the prevailing force on the cutter when the cutter wheel isin operation. A boss receiving recess 1604 is shaped to receive the boss1602. As shown, the boss 1602 has a non-planar reaction surface 1610that has a plurality of contact surface sections 1612 (two of the fivesections are labeled for purposes of clarity) that are configured toengage or contact a non-planar sidewall 1614 of the recess 1604 at aforce-transfer interface 1606. It will be appreciated that theforce-transfer interface 1606 is defined by the reaction surface 1610 ofthe boss 1602 and the sidewall 1614 of the boss receiving recess 1604,and that the reaction force is in a direction that is opposite thedirection the force F. The clearance at the force-transfer interface1606 when force F is not applied (e.g. when the cutter wheel is not inoperation) is small (or zero) such that the force F is transferred tothe wear plate via contact of the boss 1602 with the boss receivingrecess 1604.

FIG. 17 illustrates an exemplary cutter 1700 (e.g., consistent withcutters 916, 920) with a single fastener mounting aperture 1702 and asingle cylindrical boss 1704 that is offset from the aperture 1702(e.g., inline with a central longitudinal plane of the cutter 1700). Thesingle fastener mounting aperture 1702 is similar to thefastener-mounting aperture 614. As such, the description of thefastener-mounting aperture 614 applies equally to the discussion of thefastener-mounting aperture 1702. The boss 1704 is cylindrical andtherefore is similar in profile to the boss 1502(1), discussed above,and thus would mate with a boss receiving recess having a shape similarto the boss receiving recess 1504(1). Cutter 1700 includes a first orcutter end 1708 that receives the prevailing force and a second ortrailing end 1710 that is opposite the first end 1708. The cutter 1700has a body that generally tapers from the first end toward the secondend in one or more planes to reduce drag on the material to be cutduring operation of the cutter wheel. The force-transfer interface isthe same as the force-transfer interface described relative to FIG. 15for one of the bosses 1502(1), 1502(2).

FIGS. 18A-C illustrate another exemplary cutter 1800 including a body1801 that has a single fastener mounting aperture 1802, a single boss1804, and cutter tip 1806. The cutter tip 1806 can include one or morecarbide inserts (two are shown), or another type of cutter tip that isadequate for material reduction. The cutter body 1801 has a first orcutter end 1808 and a second or trailing end 1810 that generally tapersfrom the first end 1808 toward the second end 1810 in one or more planesto reduce drag on the material to be cut during operation of the cutterwheel. The cutter body 1801 also has a first side 1812 and a second side1814 opposite the first side 1812. The cutter body 1801 has a length Lbetween the first end 1808 and the second end 1810, and a width Wbetween the first side 1812 and the second side 1814. With reference toFIG. 18C, the width W of the cutter body 1801 generally varies from thefirst end 1808 toward the second end 1810. For purposes of the claims,the width W is defined as the maximum distance measured laterally acrossthe cutter body 1801 between the first side 1812 and the second side1814. The cutter body 1801 further has a mounting surface 1816 that islocated on the bottom of the body 1801 (when viewed in FIG. 18B). Themounting surface 1816 (which is part of the overall inner surface of thecutter 1800) generally defines a plane 1818. The mounting aperture 1802is disposed between the first end 1808 and the second end 1810 and isfurther disposed between the first side 1812 and the second side 1814.

The boss 1804 has a rectangular profile and is generally located closerto the first end 1808 than the second end 1810. As shown, the boss 1804is located adjacent or on the first end 1808 and is offset from themounting aperture 1802 such that the fastener axis 1809 does notintersect the boss 1804. For example, the fastener axis 1809, asillustrated, is perpendicular to the plane 1818. The boss 1804 extendsoutward from the plane 1818 and has a first surface 1820 (FIG. 18C) onthe first end 1808 and a second surface 1822 that is generally oppositethe first surface 1820 and that faces the second end 1810. The boss 1804has a first dimension that is measured along the length L and a seconddimension that is measured along the width W. The second dimension islarger than the first dimension such that the boss 1804 is wider (alongwidth W) than the boss 1804 is long (along the length L). In general,the boss 1804 has a second dimension that is at least 50% of the widthW, although the second dimension can be smaller than 50% of the width W(e.g., at least 25% of the width W).

The second surface 1822 defines a planar reaction surface that iselongated along the width and that is configured to engage a sidewall ofthe corresponding recess in a wear plate or drive plate. Consistent withwhat is described with regard to FIG. 13, the force-transfer interfaceis defined by the reaction surface 1822 of the boss 1804 and thesidewall of the boss receiving recess. The second surface 1822 is angledat a first angle 1824 relative to the plane 1818 defined by the mountingsurface 1816. The first angle 1824 is equal to, or within a tolerancelevel of (e.g. within 5 degrees), the angle of the sidewall of therespective boss receiving recess. As shown in FIG. 18B, the first angleis 90 degrees (i.e. perpendicular to the plane 1818). The illustratedmounting surface 1816 is oriented parallel to the prevailing directionof dominant force (shown by dominant force vector 1826) that acts on thecutter 1800 during operation. The dominant force vector 1826 is oppositethe direction of travel of the cutter. It will be appreciated that themounting surface 1816 may not be completely parallel to the dominantforce vector during operation but will be substantially parallel withintolerances (e.g., 5 degrees). At least a portion of the second surface1822 (e.g., the entirety of the surface 1822 as shown in FIGS. 18B and18D) defines a plane that is oriented vertically when the cutter 1800first engages an object via the cutter edge during operation. As shownin FIG. 18B, the dominant force vector 1826 is perpendicular to thesecond surface 1822.

The cutter 1800 also includes an optional relief notch 1828 at thevertex of the contact surface 1822 and the mounting surface 1816. Therelief notch 1828 prevents undesirable loading when the intersectionbetween the contact surface 1822 and mounting surface 1816 is imperfect.The relief notch 1828 also enables full contact between the boss contactsurface 1822 and the mating sidewall surface of the boss receivingrecess without any edge treatment (e.g. chamfer or fillet) required atthe intersection of the mounting and sidewall surfaces of the bossreceiving recess. This allows the mounting and sidewall surfaces of theboss receiving recess to have a square corner, greatly simplifying themanufacture of the boss receiving recess.

FIG. 18D illustrates a cutter 1830 that is nearly identical to thecutter 1800. Features of the cutter 1830 that are the same as the cutter1800 have the same reference numerals. The only difference between thecutter 1830 and the cutter 1800 is that the second surface 1822 (i.e.the reaction surface) has an angle relative to the plane 1818 that isless than 90 degrees (i.e. an acute angle relative to the mountingsurface 1816). The angle of the surface 1822 can assist with resistingtensile forces that may be experienced by the fastener during operation.It should be appreciated that any of the cutters described herein mayhave an acute angle configuration, even if not expressly described.

Referring to FIGS. 18B and 18D, the cutter tip 1806 first engages theobject along the dominant force vector 1826, which is tangential to thegenerally circular rotation of the wheel and thus perpendicular to aplane 1832 extending through the cutter tip 1806. The cutter tip 1806 ispositioned on the first end 1808 and has a cutter edge that lies in acutting plane 1834. The cutting plane 1834 is acutely angled relative tothe dominant force vector 1826. Stated another way, at a point of impactof the cutter edge with material to be reduced, the cutting plane 1834is angled forward in the direction of travel of the cutter (i.e. thecutter has a positive rake angle 1836). However, in other embodiments,the rake angle could be negative or zero.

FIGS. 19A-D illustrate another exemplary cutter 1900 including a body1901 that has a single fastener mounting aperture 1902, a single boss1904, and a cutter tip 1906. The cutter tip 1906 can include one or morecarbide inserts (two are shown), or another type of cutter tip. Thecutter body 1901 has a first or cutter end 1908 and a second or trailingend 1910 that generally tapers from the first end 1908 toward the secondend 1910 in one or more planes to reduce drag on the material to be cutduring operation of the cutter wheel. The cutter body 1901 also has afirst side 1912 and a second side 1914 opposite the first side 1912. Thecutter body 1901 has a length L between the first end 1908 and thesecond end 1910 (FIG. 19B), and a width W between the first side 1912and the second side 1914 (FIG. 19C). The width W of the cutter body 1901generally varies from the first end 1908 toward the second end 1910. Forpurposes of the claims, the width W is defined as the maximum distancemeasured laterally across the cutter body 1901 between the first side1912 and the second side 1914. The cutter body 1901 further has amounting surface 1916 that is located on the bottom of the body 1901(when viewed in FIG. 19B). The mounting surface 1916 (which is part ofthe overall inner surface of the cutter 1900) generally defines a plane1918. The mounting aperture 1902 is disposed between the first end 1908and the second end 1910 and is further disposed between the first side1912 and the second side 1914.

The boss 1904 has a polygonal profile and is generally located closer tothe first end 1908 than the second end 1910. As shown, the boss 1904 islocated adjacent or on the first end 1908 and is offset from themounting aperture 1902 such that the fastener axis 1909 does notintersect the boss 1904. For example, the fastener axis 1909, asillustrated, is perpendicular to the plane 1918. The boss 1904 extendsoutward from the plane 1918 and has a first surface 1920 (FIG. 19C) onthe first end 1908 and a second surface 1922 that is generally oppositethe first surface 1920 and that faces the second end 1910. The boss 1904has a first dimension that is measured along the length L and a seconddimension that is measured along the width W. The second dimension islarger than the first dimension such that the boss 1904 is wider (alongwidth W) than the boss 1904 is long (along the length (L). In general,the boss 1904 has a second dimension that is at least 50% of the widthW, although the second dimension can be smaller than 50% of the width W(e.g., at least 25% of the width W).

The second surface 1922 is non-planar and elongated along the width, andhas a plurality of reaction surface sections 1922 a-e that areconfigured to engage a sidewall 1923 of the corresponding recess on themounting structure (e.g., in a mounting bracket, a wear plate, or driveplate (see FIG. 19D)). Elongated along the width means that thenon-planar portions or sections of the second surface 1922 result in anincreased overall contact or engagement length as compared to a planarsecond surface that would extend directly across the entire width. Asillustrated, the second surface 1922 is recessed toward the first end1908 (i.e. the reaction surface sections cooperate to define a ‘pocket’)and nests onto a corresponding ‘bump’ defined by the sidewall 1923.Consistent with what is described with regard to FIG. 16, theforce-transfer interface is defined by the reaction surface sections1922 a-e of the boss 1904 and the sidewall 1923 of the boss receivingrecess. That is, in response to a force acting on the cutter 1900, oneor more of the reaction surface sections 1922 a-e are configured tocontact the sidewall 1923 of the recess to transfer the force to theplate. The complementary non-planar surfaces 1922, 1923 of the cutter1900 and the mounting structure facilitate effective transfer of theforces acting on the cutter even with minor differences in manufacturingtolerances between the surfaces, and even when the force is notcompletely parallel to the mounting surface 1916. Stated another way,the non-planar surfaces of the cutter 1900 and the mounting structurecooperate to minimize any moment imparted on the cutter 1900 duringoperation that may tend to dislodge the cutter 1900 from the mountingstructure.

Referring to FIG. 19B, the second surface 1922 is angled at a firstangle 1924 relative to the plane 1918 defined by the mounting surface1916. The first angle 1924 is equal to, or within a tolerance level of(e.g. within 5 degrees), the angle of the sidewall of the respectiveboss receiving recess. As shown, the first angle is approximately 90degrees (i.e. perpendicular to the plane 1918), although the angle canbe above or below 90 degrees. The illustrated mounting surface 1916 isoriented parallel to the prevailing direction of dominant force (shownby dominant force vector 1926) that acts on the cutter 1900 duringoperation. The reaction surface sections 1922 a-e define planes that areoriented vertically when the cutter 1900 first engages an object via thecutter edge during operation. As shown in FIG. 19B, the dominant forcevector 1926 is perpendicular to some, but not all, of the reactionsurface sections 1922 a-e.

The cutter 1900 also includes an optional relief notch 1928 at thevertex of the contact surface 1922 and the mounting surface 1916. Therelief notch 1928 prevents undesirable loading when the intersectionbetween the contact surface 1922 and mounting surface 1916 is imperfect.The relief notch 1928 also enables full contact between the boss contactsurface 1922 and the mating sidewall surface 1923 of the boss receivingrecess without any edge treatment (e.g. chamfer or fillet) required atthe intersection of the mounting and sidewall surfaces of the bossreceiving recess. This allows the mounting and sidewall surfaces of theboss receiving recess to have a square corner, greatly simplifying themanufacture of the boss receiving recess.

Referring to FIG. 19B, the cutter tip 1906 first engages the objectalong the dominant force vector 1926, which is tangential to thegenerally circular rotation of the wheel and thus perpendicular to aplane 1932 extending through the cutter tip 1906. The cutter tip 1906 ispositioned on the first end 1908 and has a cutter edge that lies in acutting plane 1934. The cutting plane 1934 is acutely angled relative tothe dominant force vector 1926. Stated another way, at a point of impactof the cutter edge with material to be reduced, the cutting plane 1934is angled forward in the direction of travel of the cutter (i.e. thecutter has a positive rake angle 1936).

FIGS. 32A-D illustrate another exemplary cutter 3200 including a body3201 that has a single fastener mounting aperture 3202, a single boss3204, and cutter tip 3206. The cutter tip 3206 can include one or morecarbide inserts (two are shown), or another type of cutter tip. Thecutter body 3201 has a first or cutter end 3208 and a second or trailingend 3210 that generally tapers from the first end 3208 toward the secondend 3210 in one or more planes to reduce drag on the material to be cutduring operation of the cutter wheel. The cutter body 3201 also has afirst side 3212 and a second side 3214 opposite the first side 3212. Thecutter body 3201 has a length L between the first end 3208 and thesecond end 3210 (FIG. 32B), and a width W between the first side 3212and the second side 3214 (FIG. 32C). The width W of the cutter body 3201generally varies from the first end 3208 toward the second end 3210. Forpurposes of the claims, the width W is defined as the maximum distancemeasured laterally across the cutter body 3201 between the first side3212 and the second side 3214. The cutter body 3201 further has amounting surface 3216 that is located on the bottom of the body 3201(when viewed in FIG. 32B). The mounting surface 3216 (which is part ofthe overall inner surface of the cutter 3200) generally defines a plane3218. The mounting aperture 3202 is disposed between the first end 3208and the second end 3210 and is further disposed between the first side3212 and the second side 3214.

The boss 3204 has a polygonal profile and is generally located closer tothe first end 3208 than the second end 3210. As shown, the boss 3204 islocated adjacent or on the first end 3208 and is offset from themounting aperture 3202 such that the fastener axis 3209 does notintersect the boss 3204. For example, the fastener axis 3209, asillustrated, is perpendicular to the plane 3218. The boss 3204 extendsoutward from the plane 3218 and has a first surface 3220 (FIG. 32C) onthe first end 3208 and a second surface 3222 that is generally oppositethe first surface 3220 and that faces the second end 3210. The boss 3204has a first dimension that is measured along the length L and a seconddimension that is measured along the width W. The second dimension islarger than the first dimension such that the boss 3204 is wider (alongwidth W) than the boss 3204 is long (along the length (L). In general,the boss 3204 has a second dimension that is at least 50% of the widthW, although the second dimension can be smaller than 50% of the width W(e.g., at least 25% of the width W).

The second surface 3222 is non-planar and elongated along the width, andhas a plurality of reaction surface sections 3222 a-e that areconfigured to engage a sidewall 3223 of the corresponding recess on themounting structure (e.g., in a mounting bracket, a wear plate, or driveplate (see FIG. 32D)). As illustrated, the second surface 3222 projectstoward the aperture 3202 (i.e. the reaction surface sections cooperateto define a ‘bump’) and nests onto a corresponding ‘pocket’ defined bythe sidewall 3223. Consistent with what is described with regard to FIG.13, the force-transfer interface is defined by the reaction surfacesections 3222 a-e of the boss 3204 and the sidewall 3223 of the bossreceiving recess. That is, in response to a force acting on the cutter3200, one or more of the reaction surface sections 3222 a-e areconfigured to contact the sidewall 3223 of the recess to transfer theforce to the plate. The complementary non-planar surfaces 3222, 3223 ofthe cutter 3200 and the mounting structure facilitate effective transferof the forces acting on the cutter even with minor differences inmanufacturing tolerances between the surfaces, and even when the forceis not completely parallel to the mounting surface 3216. Stated anotherway, the non-planar surfaces 3222, 3223 of the cutter 3200 and themounting structure cooperate to minimize any moment imparted on thecutter 3200 during operation that may tend to dislodge the cutter 3200from the mounting structure.

Referring to FIG. 32B, the second surface 3222 is angled at a firstangle 3224 relative to the plane 3218 defined by the mounting surface3216. The first angle 3224 is equal to, or within a tolerance level of(e.g. within 5 degrees), the angle of the sidewall of the respectiveboss receiving recess. As shown, the first angle is approximately 90degrees (i.e. perpendicular to the plane 3218), although the angle canbe above or below 90 degrees. The illustrated mounting surface 3216 isoriented parallel to the prevailing direction of dominant force (shownby dominant force vector 3226) that acts on the cutter 3200 duringoperation. The reaction surface sections 3222 a-e define planes that areoriented vertically when the cutter 3200 first engages an object via thecutter edge during operation. As shown in FIG. 32B, the dominant forcevector 3226 is perpendicular to some, but not all, of the reactionsurface sections 3222 a-e.

The cutter 3200 also includes an optional relief notch 3228 at thevertex of the contact surface 3222 and the mounting surface 3216. Therelief notch 3228 prevents undesirable loading when the intersectionbetween the contact surface 3222 and mounting surface 3216 is imperfect.The relief notch 3228 also enables full contact between the boss contactsurface 3222 and the mating sidewall surface 3223 of the boss receivingrecess without any edge treatment (e.g. chamfer or fillet) required atthe intersection of the mounting and sidewall surfaces of the bossreceiving recess. This allows the mounting and sidewall surfaces of theboss receiving recess to have a square corner, greatly simplifying themanufacture of the boss receiving recess.

Referring to FIG. 32B, the cutter tip 3206 first engages the objectalong the dominant force vector 3226, which is tangential to thegenerally circular rotation of the wheel and thus perpendicular to aplane 3232 extending through the cutter tip 3206. The cutter tip 3206 ispositioned on the first end 3208 and has a cutter edge that lies in acutting plane 3234. The cutting plane 3234 is acutely angled relative tothe dominant force vector 3226. Stated another way, at a point of impactof the cutter edge with material to be reduced, the cutting plane 3234is angled forward in the direction of travel of the cutter (i.e. thecutter has a positive rake angle 3236).

FIGS. 33A-33C illustrate dominant force vectors for differentarrangements of cutters described herein on cutter wheels, drums, orrotors (e.g., the wheels described relative to FIGS. 8, 10).

The exemplary bosses and corresponding recesses described relative toand illustrated in FIGS. 13, 14, 16, 18A-D, 19A-D, and 32A-D each have asurface-contact force-transfer interface that is defined by one or moresurfaces of these features, whereas the exemplary bosses andcorresponding recesses described relative to and illustrated in FIGS. 15and 17 each define a line-contact force-transfer interface. That is, thesurface-contact force-transfer interface acts primarily along the entirereaction surface and the recess wall, while the line-contactforce-transfer interface acts primarily on a single point-contactbetween the boss and the recess. In general, it is preferred that thereaction surface(s) and the corresponding surface defined by the bossreceiving recess are normal (perpendicular) to the direction of travelof the cutter during operation.

It will be appreciated that the boss may have other types of non-planarreaction surfaces while remaining within the scope of the presentinvention. For example, the boss may have any quantity of reactionsurface sections (e.g., one, two, three, four, five (as shown in FIGS.19A-D and 32A-D), more than five). The boss may have a partially orfully curved reaction surface, or the boss may have a reaction surfacethat is angled such that the reaction surface is closer to the first endon one side of the cutter than on the other side. Other shapes for thereaction surface are possible and considered herein. The above describedcutters, bosses, and boss receiving recesses are not limiting in scopeand the boss could have any shape without departing from the presentinvention.

The cutters described with regard to various embodiments of the presentinvention have a reaction surface and complementary surface in the bossreceiving recess that are generally perpendicular to the direction oftravel of the cutter when mounted on a wheel. This arrangementsurprisingly allows for a single, small fastener (e.g., no larger than0.75 inches, or a fastener aperture that is no more than ⅓ of the widthW) to be used to attach the cutter to a cutter wheel. Before the presentinvention, for large stump cutter machines (e.g., 300 HP), it wasgenerally believed that at least one large fastener (e.g., sized at0.875 inches or larger), and likely multiple fasteners were needed toadequately resist the loads that are applied to the cutter duringoperation. The fastener mounting apertures described relative to theFigures (e.g., FIGS. 18A-D, FIGS. 19A-D, and FIGS. 32A-D) surprisinglycan be sized to receive a fastener with a 0.75 inch diameter shaft orsmaller while still adequately resisting shear. It is believed that thisis due to the surface-contact force-transfer interface between the bossand the wheel. Initially, it was expected that, with a relatively smallfastener (and correspondingly sized aperture), additional bosses may beneeded to maintain the position or orientation of the cutter on thewheel (e.g., to resist any moment acting on the cutter). However, aftertesting, it was determined that a fastener sized with a 0.75 inch shaftproved adequate for maintaining the position of a cutter with a bossthat has a reaction surface consistent with the embodiments describedherein. In fact, for some cutters, the fastener can be as small as 0.375inches. Also, unlike existing cutter wheels with cutters that areattached to cutter wheels with approximately 98,000 lb-f clamp load(with two ⅞″ bolts torqued to 500 ft*lbf), cutters including the bossesdescribed herein can be attached to cutter wheels with approximately40,000 lb-f clamp load (with a single ¾″ bolt torqued to 350 ft*lbf). Asingle fastener and lower torque requirements is beneficial forminimizing the time it takes to replace a cutter, as well as the abilityto use a smaller torque wrench while doing so. The same discussion aboveapplies equally to smaller cutter sizes according to the invention, usedon smaller stump cutter machines (e.g., below 100 HP), such thatfastener sizes can be smaller than those previously used with prior artcutters on those smaller machines.

The cutter wheels described with regard to FIGS. 1-12 may includeadditional or other features that provide wear prevention associatedwith the cutter wheel 114. For example, FIG. 20 depicts a cutter wheel2000 including a plurality of drive plate wear prevention cutters 2060,sometimes referred to as plunge cutters. FIG. 21 depicts a close-up viewof one of the drive plate wear prevention cutter 2060. FIG. 22 depicts aprofile view of the cutter wheel 2000 showing the profile of the driveplate 2002 including a mounting feature 2202 for mounting the driveplate wear prevention cutter 2060. FIGS. 20-22 are best viewed togetherwith the following description.

The cutter wheel 2000 is similar to the cutter wheel 114, discussedabove with respects to FIGS. 2-5, the cutter wheel 900, discussedrelative to FIGS. 9-12, and may include any of the above discussedfeatures of cutter wheel 114 or 900. Similar parts have been givensimilar part numbers of the 2000 series. The same description set forthabove for the cutter wheels 114, and 900 apply equally to the cutterwheel 2000 and will not be repeated herein.

One or more of a plurality of drive plate wear prevention cutters orplunge cutters 2060 may be mounted to an outer profile of the driveplate 2002. The plurality of drive plate wear prevention cutters 2060operate to prevent wear on the drive plate 2002 by reducing any materialthat would come in contact with the outer profile of the drive plate2002. FIGS. 20-22 show four drive plate wear prevention cutters 2060equally spaced around the profile of the drive plate 2002, such thatthere is a single drive plate wear prevention cutter 2060 adjacent eachwear plate segment 2010. However, in embodiments, there may be more orfewer drive plate wear prevention cutters 2060 without departing fromthe scope hereof.

As shown in FIG. 22, the mounting feature 2202 is integral to the driveplate 2002. In other embodiments, the mounting feature 2202 may bewelded or attached to the drive plate 2002. In some embodiments themounting feature 2202 may be bolted to the wear plates 2004. The driveplate wear prevention cutters 2060 may be mounted to the mountingfeature 2202 via a fastener 2204. Moreover, the distance from the centerof the cutter wheel 2000 to the outer tip of the outer-most cutter 2016(shown as line 2206 in FIG. 22) is greater than the distance from thecenter of the cutter wheel 2000 to the outer tip of the drive plate wearprevention cutters 2060 (shown as line 2208 in FIG. 22). This providesthe advantage that the drive plate wear prevention cutters 2060 are notsubjected to significant forces during operation because the cutters2016 function as the primary material reduction features on the cutterwheel 2000.

FIG. 23 depicts a cutter wheel 2300 including a plurality of drive platewear prevention cutters 2360. FIG. 24 depicts a right elevation view ofone of the wear plates segments 2310, including a mounting feature 2402for receiving the drive plate wear prevention cutters 2360. FIG. 25depicts a profile view of the cutter wheel 2300 including an outer edgethat ramps toward the tip of the drive plate wear prevention cutter2360. FIGS. 23-25 are best viewed together with the followingdescription.

The cutter wheel 2300 is similar to the cutter wheel 114, discussedabove with respects to FIGS. 2-5, the cutter wheel 900, discussedrelative to FIGS. 9-12, and the cutter wheel 2000 discussed aboverelative to FIGS. 20-22, and may include any of the above discussedfeatures of cutter wheel 114, 900, or 2000. Similar parts have beengiven similar part numbers of the 2300 series. The same description setforth above for the cutter wheels 114, 900, and 2000 apply equally tothe cutter wheel 2300 and will not be repeated herein.

One or more drive plate wear prevention cutters or plunge cutters 2360may be mounted at an outer profile of the drive plate 2302. Theplurality of drive plate wear prevention cutters 2360 operate to preventwear on the drive plate 2302 by reducing any material that would come incontact with the outer profile of the drive plate 2302. FIGS. 23-25 showfour drive plate wear prevention cutters 2360 equally spaced around theprofile of the drive plate 2302, such that there is a single drive platewear prevention cutters 2360 adjacent each wear plate segment 2310.However, in embodiments, there may be more or fewer drive plate wearprevention cutters 2360 without departing from the scope hereof.

The drive plate wear prevention cutters 2360 differ from the drive platewear prevention cutters 2060, discussed above, in that they are notmounted at a mounting feature (e.g. mounting feature 2202) on the driveplate, but instead are mounted in similar manner to cutters 2316 in thatthey are within a mounting feature 2402 (e.g. a notch, or recess) on theouter profile of the wear plate 2304 (or a segment thereof).Furthermore, the drive plate wear prevention cutters 2360 include twocutters that mount at each side of the drive plate 2302, and include aportion that traverses the outer edge of the drive plate 2302 to protectthe outer edge from wear during operation.

As shown in FIG. 24, the mounting feature 2402 is a notch, recess, orpartial aperture within the wear plate 2304 (or a segment 2310 thereof).The drive plate wear prevention cutters 2360 may be mounted within themounting feature 2402 in a similar manner to the cutters 2316 beingmounted in a boss receiving recess providing a contact interface betweenthe drive plate wear prevention cutters 2360 and a trailing edge 2404and/or an upper edge 2406. In other words, the trailing edge 2404 and/orthe upper edge 2406 of the mounting feature 2402 may be configured toprovide a contact interface that transfers predominant force affected onthe drive plate wear prevention cutters 2360 to the wear plate 2304, asopposed to the drive plate 2302.

As shown in FIG. 25, one or both of the wear plate 2304, and the driveplate 2302 may include an outer edge 2504 respectively, that rampstoward an outer tip of the drive plate wear prevention cutter 2360. Thisreduces the predominant force affected on the leading edge 2506 of thedrive plate wear prevention cutter 2360. Accordingly, the ramp preventsmaterial from wedging on the underside of the crossover portion of thewear prevention cutter 2360 between the wear prevention cutter 2360 andthe drive plate 2302. Thus, breaking of the crossover portion of thedrive plate wear prevention cutter 2360 is prevented.

Moreover, the distance from the center of the cutter wheel 2300 to theouter tip of the outer-most cutter 2316 (shown as line 2508 in FIG. 25)is greater than the distance from the center of the cutter wheel 2300 tothe outer tip of the drive plate wear prevention cutters 2360 (shown asline 2510 in FIG. 25). This provides the advantage that the drive platewear prevention cutters 2360 are not subjected to significant forcesduring operation because the cutters 2316 function as the primarymaterial reduction features on the cutter wheel 2300.

The above described features provide many advantages over conventionalmaterial reducing cutter wheels. For example, by creating the boss toengage a boss receiving recess configuration, discussed above, withinthe wear plate (e.g. wear plates 204), the shear force load path isthrough the engagement of the boss and the boss receiving recess (whichmay be in the wear plate, or even in the drive plate in someembodiments) as opposed to on the fastener itself. As such, the fasteneris less likely to break due to said shear force. In some embodiments,the boss and boss receiving recess may cooperate to prevent rotation ofthe cutter when operating the cutter wheel (which is particularlyadvantageous if a single fastener per cutter is used). Moreover, thewear plates discussed herein are less costly to manufacture as comparedto manufacturing a single cutter wheel. The wear plates are replaceablethereby increasing the lifespan of the drive plate of the presentlydescribed cutter wheel. Worn sockets within the wear plates may beeasily replaced by replacing the entire wear plate, or a wear platesegment thereof. Conventional cutter wheels may be hard-faced whichrequires post balancing. By using wear plates as discussed herein,balancing may be eliminated, or more easily performed by manipulatingthe given wear plate or altering a segment thereof.

FIG. 26 depicts a perspective view of a cutter wheel 2600 including awear prevention feature 2660 that may be used in any of the abovedescribed cutter wheels, in embodiments. FIG. 27 depicts a cross sectionof the cutter wheel 2600.

A wear prevention feature 2660 may be bolted or attached between the twowear plates 2604 to protect the drive plate 2602 from wear. In general,wear occurs on radially outward, leading edge features of the driveplate 2602. FIG. 26 shows a wear prevention feature 2660 in the form ofa bolt 2662 passing through aligned holes in both the first and secondwear plates 2604. It is secured with a nut 2664 on the opposite side. Asshown in FIG. 27, the shank of bolt 2662, has a radial path greater thanthe radial path of the trailing feature of the drive plate 2602. Thisallows the shank of the bolt 2662 to wear, while the drive plate 2602 isprotected. While significant wear will occur on the bolt 2662, the boltand the nut 2664 are relatively inexpensive, common and easy to replace.Proud portions 2702 (FIG. 27) of the wear plates 2604 will seesignificant wear, but since the proud portions 2702 are of a wearresistant material and are also replaceable, some wear is acceptable.The proud portions 2702 of the wear plate 2604 may be shaped to scoopmaterial out of the way or even cut material and prevent material fromsliding and causing increased rate of wear. Likewise, the profile of thedrive plate 2602 is stepped, as shown in FIG. 27, to encourage materialto be ejected rather than slide along and increase the rate of wear. Thepatterns of the features of the wear prevention features 2660 aredesigned such that when they wear, the wheel retains balance. Thepositions of the wear prevention features 2660, the profile of the wearplates 2604 and the drive plate 2602 are designed to enhance a chipevacuation path 2704 axially around the cutter.

The wear of the bolt 2662 shank may be enhanced with a roller 2666 or anindexable sleeve 2668. The roller 2662 is narrower than the drive plate2602 and is free to rotate about the bolt 2662 axis. This allows wear tooccur on all the around the entire circumference of roller 2666 insteadof one side of the bolt 2662. The roller 2666 may be of a hardenedmaterial to increase wear resistance. The indexable sleeve 2668 isprevented from rotating by a feature 2706 (FIG. 27) of the drive plate2602. The feature 2706 may be one of the steps on the outer profile ofthe drive plate 2602. If one side of the indexable sleeve 2668 wears,the bolt 2662 may be removed, the indexable sleeve 2668 rotated to a newside and the bolt 2662 reinserted. Both the roller 2666 and indexablesleeve 2668 is designed so that it has a radial path greater than theradial path of the trailing feature (e.g. feature 2706) of the driveplate (FIG. 27).

Referring now to FIGS. 28-31, rotating drum 2800 may be used in brushchipper machines, tub grinders, or mulchers for example. Drum 2800 maygenerally represent a rotor used on a mulcher head without departingfrom the scope hereof. A plurality of cutter assemblies 2802 are mountedto the rotating drum 2800. The rotating drum 2800 may be a cylindricaldrum that is coupled to a drive system of the grinding machine. Theplurality of cutter assemblies 2802 may be mounted in a helicalconfiguration (shown in FIG. 28) about the outer surface of the drum, orin any other configuration desired.

Referring to FIG. 29, the plurality of cutter assemblies 2802 include acutter 2902 mounted to a cutter mount 2904. The cutter 2902 is mountedvia a single fastener 2906 that is coupled to a cutter fastener insert2908. The cutter 2902 and cutter fastener insert 2908 may have varying,corresponding shapes consistent with the bosses described herein. Itshould be appreciated that there may be more than a single fastener2906, and the cutter fastener 2906 may attach directly to the cuttermount 2094 instead of to the cutter fastener insert 2908.

The cutter 2902 may be any of the cutters described herein. In theparticular embodiment shown in FIGS. 29-31, the cutter 2902 includes an“M” shaped boss 2910.

The cutter mount 2904 may be similar to the cutter mount 921 discussedabove. The cutter mount 2904 may thus have any of the features discussedabove relative to cutter mount 921, and the cutter mount 921 may thushave any of the features discussed below relative to the cutter mount2904. The cutter mount 2904 may be welded, adhered, bolted, nailed,screwed, riveted, or otherwise attached to the rotating drum 2800.

Referring to FIG. 30, the cutter mount 2904 may include a top surface3002, two side surfaces 3004, 3006, a rear surface 3008, and a frontsurface 3010, and a bottom surface 3012. The top surface 3002 mayinclude a fastener aperture 3013 that may be threaded or not threaded.The fastener aperture 3013 may be threaded when the fastener 2906couples directly to the cutter mount 2904, and unthreaded when thefastener 2906 couples to the cutter fastener insert 2908. The topsurface 3002 may further include a boss receiving feature 3014 that iscomplementary to the boss 2910 of the cutter 2902. The boss receivingfeature 3014 is shown in FIG. 30 as a sidewall cut into the top surface3002 that matches the boss 2910 (e.g., similar to or the same as thebosses described with regard to FIGS. 18A-D, 19A-D, or 32A-D). The angleof the sidewall relative to the top surface 3002 may be equal to theangle of the boss 2910 relative to the inner surface of the cutter 2902(e.g., the surface that abuts the cutter mount 2904 when the cutter 2902is mounted thereto. In the embodiment shown in FIGS. 28-31, the bossreceiving feature 3014 does not extend along the sides of the boss 2910.As such, the non-planar boss receiving feature 3014 cooperates with thenon-planar boss 2910 to prevent rotation of the cutter 2902 relative tothe cutter mount 2904. The bottom surface 3012 may be curved to matchthe curvature of the drum 2800.

In some embodiments, the fastener insert 2908 may also be a hex nut. Thefastener aperture 2912 may correspondingly be rectangular or hexagonalto match the profile of the nut, and be in the rear, front, or sidesurfaces 3010, 3008, 3004-3006, respectively. The front surface 3010 isshown as orthogonal or perpendicular to the side surfaces 3004, 3006. Itshould be appreciated that any of these surfaces may be angled (such astapered) to prevent drag during operation.

As shown in FIG. 29, the rear surface 3008 may have an aperture 2912into which the cutter fastener insert 2908 is positioned. It should beappreciated that the aperture 2912 may be on the side or front surfacesalternatively (or additionally) without departing from the scope hereof.The aperture 2912 may be hexagonal to match the shape of the cutterfastener insert 2908. As shown in FIG. 31, the cutter fastener insert2908 may include one or more fastener apertures 3102. Two fastenerapertures 3102 are shown in FIG. 31, however there may be more or fewerwithout departing from the scope hereof. The two fastener apertureembodiment shown in FIG. 31 provides the advantage that the insert 2908may be removed and reversed should one of the fastener apertures 3102become damaged during operation.

Those of skill in the art will understand that the concept of alaminated cutter wheel (i.e., with a drive plate and one or more wearplates) is useful even with existing-style cutters. FIGS. 34 and 35illustrate a cutter wheel 3400 having cutters 3416 that are Vermeer®Yellow Jackets™ cutters. The cutter wheel 3400 includes a drive plate3402 and wear plates 3404, with the features and characteristics asdescribed above. In the illustrated arrangement, the cutters 3416 do notinclude any bosses or reaction surfaces that engage any boss-receivingapertures or features of the wear plates 3404. Instead, as shown in FIG.35, the cutters 3416 are secured using the two fasteners 3418. Thecompression created between the opposed cutters 3416 creates thefriction that secures the wear plates 3404 relative to the drive plate3402. The cutter wheel 3400, like all of the laminated cutter wheelsdescribed herein, is re-buildable, with replaceable wear plates 3404 andcutters 3416, thereby lengthening the life expectancy of the drive plate3402 as compared to existing, non-laminated cutter wheel assemblies. Ifportions of the cutter wheel 3400 become worn or damaged, those portionscan be easily replaced to re-build the cutter wheel 3400.

FIGS. 36-39 illustrate yet another cutter wheel 3600 embodying theinvention. The cutter wheel 3600 is illustrated as being a laminatedcutter wheel and is similar in many respects to the cutter wheel 114,discussed above with respects to FIGS. 2-5, the cutter wheel 900,discussed relative to FIGS. 9-12, the cutter wheel 2000 discussed aboverelative to FIGS. 20-22, and the cutter wheel 2300 discussed aboverelative to FIGS. 23-25, and may include any of the above discussedfeatures of cutter wheel 114, 900, 2000, or 2300. Similar parts havebeen given similar part numbers of the 3600 series. The same descriptionset forth above for the cutter wheels 114, 900, 2000, and 2300 can applyequally to the cutter wheel 3600 and will not be repeated herein.

The cutter wheel 3600 is illustrated with a drive plate 3602 and aplurality of wear plates 3604 (e.g., two on each face of the drive plate3602). Alignment apertures 3612 and respective alignment fasteners areutilized to assist in securing the wear plates 3604 to the drive plate3602. The illustrated cutters 3616 are all identical to one another(with the exception of the interior of the fastener apertures 4002—e.g.,threaded versus counter-bored), but are positioned in aligned pairs onthe faces of the wear plates 3604, and also as plunge cutters positionedat the outer periphery of the cutter wheel 3600/drive plate 3602.

Significantly, the cutters 3616 (as well as the cutters 1700, 1800, and1900 discussed above) can be re-positioned to different locations on thecutter wheel 3600 when portions of the cutter tips wear. Typically,depending upon the placement of the cutter 3616 on the cutter wheel3600, one cutting edge of the cutter tip will experience the bulk of thewear. On the plunge cutters, it would be the upper or crown portion ofthe cutter tip. On the side-mounted cutters, it would be one of thecutting edges extending along one side of the cutter. Therefore, after aperiod of use, an aligned pair of side-mounted cutters 3616 can be“reversed” to the opposite faces of the cutter wheel 3600 so that anopposite cutting edge of each cutter tip is utilized. Or an aligned pairof side-mounted cutters 3616 could be repositioned to two plungecutters. The plunge cutters could be moved to an aligned pair ofside-mounted cutters 3616. This adds to the usable life of the cutters3616. Unlike some cutters in which the mounting fastener is integratedwith the cutter, the separate fasteners 3618 allow the fasteners to bere-used when the cutters 3616 are changed or moved.

As illustrated in FIG. 37, the wear plates 3604 include theboss-receiving features 3608 for positioning the respective side-mountedcutters 3616 thereon, while the plunge cutters 3616 are supported on acutter mount 3621, which, in the illustrated embodiment best shown inFIGS. 38 and 39, includes a base member 3621 a and a mount member 3621b. The drive plate 3602 includes a recess or cutout 3650 at each plungecutter position that is configured to receive the base member 3621 atherein, laterally from either face of the drive plate 3602. The basemember 3621 a need not be welded to the drive plate 3602, but insteadcan be secured in the recess 3650 via the alignment fasteners thatextend through the alignment apertures 3612. The base member 3621 aincludes an alignment aperture 3612 of its own so that the alignmentfastener used to secure the wear plates 3604 to the drive plate 3602further secures the base member 3621 a to the drive plate 3602. Thiseliminates the need to weld any portion of the mount 3621 directly tothe drive plate 3602. However, in other embodiments, the mount 3621could be welded directly to the drive plate 3602.

The mount member 3621 b is secured (e.g., welded) to the base member3621(a), and provides the boss-receiving feature 3608 for mating withthe plunge cutter 3616, as will be described in further detail below.Once the wear plate 3604 is secured to the drive plate 3602, only asmall upper portion of the base member 3621 a is visible in the recess3650.

FIGS. 40-46 illustrate the cutter 3616 in greater detail. The cutter3616 is similar in many respects to the cutter 1900 described above, andunless otherwise discussed below, the same description applies equallyfor the cutter 3616, and like reference numbers of the 4000 series havebeen used. Further detail and distinctions are noted below.

As with the cutter 1900, the second surface 4022 is non-planar andtherefore elongated along the width. Elongated along the width meansthat the non-planar portions or sections of the second surface 4022result in an increased overall contact or engagement length as comparedto a planar second surface that would extend directly across the entirewidth. The second surface 4022 has a plurality of reaction surfacesections 4022 a-e (see FIG. 45) that are configured to engage a sidewallor boss-receiving feature 3608 of the mounting structure (e.g., on awear plate, or drive plate, or mount (see FIGS. 39 and 46)). Thereaction surface sections 4022 a-e are disposed between the mountingsurface 4016 and the first end 4008, and therefore also between thefastener aperture 4002 and the first end 4008. As illustrated, thesecond surface 4022 is recessed toward the first end 4008 (i.e. thereaction surface sections cooperate to define a ‘pocket’) and nests ontoa corresponding ‘bump’ defined by the sidewall 3608.

The reaction surface section 4022 c can be referred to as an innersurface portion, while the reaction surface sections 4022 b and 4022 dcan be referred to as transition surface portions. In the illustratedembodiment, each transition surface portion 4022 b, 4022 d intersectsthe inner surface portion 4022 c at a respective end of the innersurface portion 4022 c and at an angle of between 100 and 160 degrees(e.g., 120 degrees). In the illustrated embodiment, the intersectionangles are the same at both ends of the inner surface portion 4022 csuch that the transition surface portions are symmetrical about alongitudinal axis of the cutter 3616.

The first and second sides 4012 and 4014 each include a projecting ridge4100 extending from the first end 4008 to the second end 4010. Theillustrated projecting ridges 4100 are arcuate and are formed during theforging process. The ridges 4100 result from the desired movement ofmaterial during forging to achieve the overall shape and contour of thefirst and second sides 4012, 4014 that operate to reduce drag on thecutter 3616 during cutting.

Each cutter 3616 has a cutter tip 4006 that forms a scalloped andM-shaped edge profile. The cutter tip 4006 includes a first leg portion4200 extending along the first side 4012 of the cutter 3616, a secondleg portion 4204 extending along the second side 4014, and an upper orcrown portion 4208 extending between the first and second leg portions4200, 4204. The crown portion 4208 defines, in part, the upper surfaceof the cutter 3616. The crown portion 4208 defines in its upper surfacea concavity 4212 that conforms in shape to a concavity 4216 formed inthe upper surface of the cutter body 4001 adjacent the cutter tip 4006.That is, there is a smooth transition between the concave surface 4212of the cutter tip 4006 and the concave surface 4216 on the upper surfaceof the cutter body 4001. The concavities 4212, 4216 reduce drag andfacilitate material evacuation during cutting.

The cutter tip 4006 defines a front face or cutting face 4220 that iscupped or concave such that the outermost edges of the leg portions4200, 4204 and crown portion 4208 define respective cutting edges 4224of the cutter tip 4006. These cutting edges 4224 extend along therespective sides of the cutter and lead the cutter 3616 into the surfacebeing cut. The cutter 3616 (as well as the cutters 1700, 1800, and 1900)reduces drag on the cutter wheel 3600 because all of the mounting andsupport structure of the cutter 3616 is completely “behind” or “within”the profile or footprint defined by the cutting edges 4224, or the frontface 4220, as the cutter wheel 3600 rotates. As illustrated in FIG. 37,the width of the cutting path or swath S defined by the cutting edgesand the cutting face (as measured in the same direction as the width Wof the cutter 3616) completely encompasses the width W of the cutter3616. Stated differently, no portion of the cutter, and specifically noportion of the sides of the cutter, extend in the width directionoutside of its cutting swath S. The width of cutting swath S is variablein a direction extending between the inner and outer sides of thecutter, and increases in a direction from the inner side or surface ofthe cutter toward the outer side or surface of the cutter (see FIG. 40).The sides of the cutter are configured accordingly so as to conform toand stay within the variable width of the swath S at any locationbetween the inner and outer sides. As illustrated, this is true of acutter 3616 having a fastener axis that is substantially perpendicularto the direction of rotation and the dominant force vector.

The cutting edges 4224 also experience the force providing the dominantforce vector. With reference to FIG. 47, it can be seen that the boss4004, and more specifically the engagement between the reaction surfaces4022 a-e and the boss-receiving feature 3608, opposes the dominant forcevector to maintain the position of the cutter 3616 relative to theboss-receiving feature 3608 on the wear plates 3604 (or on the mount3621). The force on the cutters 3616 is transferred from the boss 4004to the wear plate 3604. And because the wear plates 3604 arefrictionally secured to the drive plate 3602 via the compressive forcesexerted by the aligned cutter pairs, the force is transferred from thewear plates 3604 to the drive plate 3602 through the large surface areafrictional engagement between the wear plates 3604 and the drive plate3602. In this regard, the reaction surfaces 4022 a-e further operate tominimize shear force on the fastener 3618, because, similar to FIG. 7,the fastener 3618 does not directly contact the apertures in the driveplate 3602 or the wear plates 3604 through which it extends. It is theengagement between the boss 4004 and the boss-receiving feature 3608that is the positional limiter for the cutter 3616, not the engagementbetween the fastener 3618 and any aperture in the drive plate 3602 orwear plate 3604 through which the fastener 3618 extends.

Furthermore, and as clearly shown in FIGS. 47 and 48, with the cutterwheel 3600 and many of the others described above, the boss 4004 engagesthe boss-receiving feature 3608 at an outer edge or periphery of thewear plates 3604. This outer edge or periphery can be located right at achip evacuation notch or gullet location of the cutter wheel. This isdifferent from many arrangements in which a mounting feature of a cutteror an intermediate member between the cutter and the drive plate must beinserted into an aperture or recess that is completely contained insideor within an outer periphery of the cutter wheel. This allows beneficialrelative positioning of the cutting edges 4224 at or very near thisouter edge or periphery of the wear plates 3604, and therefore at orvery near the outer edge or periphery of the cutter wheel 3600. To stateit another way, the boss 4004 and the reaction surfaces 4022 a-eactually overhang a distal edge of the wear plate 3604 containing theboss-receiving feature 3608. This arrangement could likewise be used ona cutter wheel that did not incorporate wear plates. Notice again that agap is provided between the drive plate 3602 and the lowest or bottomsurface of the boss 4004. This reduces wear to the drive plate 3602 inthat the cutter 3616 does not directly contact the drive plate 3602.

In the illustrated embodiment, the cutter tip 4006 is formed from twoseparate pieces or segments 4006 a, 4006 b that are attached (e.g.,welded, brazed, adhered, etc.) to the body 4001 adjacent each other. Thesegments 4406 a, 4006 b can be carbide or other suitable material. Thesegments 4006 a, 4006 b are mirror images of one another and abut oneanother at a parting line 4228 in the crown portion 4208. In alternativeembodiments, the two cutter tip segments 4006 a and 4006 b could be oneintegrally formed cutter tip. Each segment 4006 a, 4006 b includes anarcuate transition between the cutting edge 4224 of the leg portion andthe cutting edge 4224 of the crown portion. In some embodiments, thetransitions between the cutting edges 4224 of the leg portion and thecutting edge 4224 of the crown portion are configured according to thegeometries set forth in U.S. patent application Ser. No. 16/033,667,filed Jul. 12, 2018, the entire content of which is hereby incorporatedby reference herein. As best shown in FIG. 41, the thickness of thesegments 4006 a, 4006 b increases from a distal end (i.e., lower end inFIG. 41) of the leg portions 4200, 4204 toward the crown portion 4208,such that the crown portion 4208 has a greater thickness in thelongitudinal direction of the cutter 3616 than the leg portions 4200,4204.

As shown in FIG. 43, the cutter tip segments 4006 a, 4006 b are coupledto the body 4001 and nest onto the body 4001 via a ledge 4300 on thefirst end 4008 of the body 4001. The ledge 4300 supports inner surfacesof the leg portions 4200, 4204 and the crown portion 4208 that areinwardly spaced from the cutting edges 4224. In the illustratedembodiment, the cutting edges 4224 stand proud of the remainder of thefirst end 4008 of the cutter body 4001 to lead the cutter 3616 duringcutting. The front face 4220 of the cutter tip 4006 inside of thecutting edges 4224 can transition to the inner surfaces to be generallyaligned with the adjacent remainder of the first end 4008 of the cutter3616, thereby facilitating chip removal.

Referring again to FIGS. 36-38 and 48, the cutter wheel 3600 includes aplurality of chip evacuation notches or gullets 3652 on the perimeter ofthe cutter wheel 3600 that extend through the drive plate 3602 and eachwear plate 3604. The gullets 3652 allow material that is cut by thecutters 3616 to evacuate through the gullets 3652 and release on theother side of the wheel 3600 as the cutter wheel 3600 is traversing thematerial. The gullets 3652 also reduce the recirculation of materialduring operation of the cutter wheel 3600. The material can includematerial that has been cut by the cutters 3616.

With reference to FIG. 37, the illustrated gullets 3652 include astraight segment 4400 (defined by one or more of the drive plate 3602and the wear plates 3604) defining a first leg of the gullet 3652, andan arcuate segment 4404 (defined by one or more of the drive plate 3602and the wear plates 3604) defining a second leg of the gullet 3652. Theillustrated straight segment 4400 extends substantially radiallyrelative to the cutter wheel 3600 (e.g., within about 5 degrees of aradial line extending from the mounting aperture 3606). The gullet 3652has a depth D measured from an outer periphery of the wheel adjacent thegullet 3652, and the straight segment 4400 extends to a deepest portionof the gullet 3652. In the illustrated embodiment, the depth D is atleast 1-1.5 times a maximum width of the cutter 3616.

With reference to FIGS. 47 and 48, the precise positioning of the cutter3616 relative to the gullet 3652, and more specifically to the straightsegment 4400 of the gullet 3652 can vary. Where the cutting edges 4224all lie in and define a cutter plane, that cutter plane will intersectthe drive plate 3602 along a line 4408 that is substantially parallel(e.g., within 5 degrees) to the straight segment 4400. However,depending upon the position of the boss-receiving feature 3608 relativeto the straight segment 4400, the location of the line 4408 where thecutter plane intersects with the drive plate 3602 can vary. In someembodiments, the intersection could occur right at the straight segment4400, however in other embodiments, the intersection could be rearwardor forward of the straight segment 4400 (relative to the direction ofrotation of the cutter wheel 3600). In most embodiments, at least aportion of the cutter tip 4006 is positioned forwardly (in the directionof rotation) of the straight segment 4400.

FIGS. 49 and 50 illustrate the coverage provided by the cutter tips 4006of the cutter wheel 3600. Represented is a grouping of cutters 3616 thatincludes one plunge cutter and the four cutter pairs trailing the plungecutter. In the embodiment illustrated in FIG. 36, the cutter wheel 3600includes two groupings of cutters 3616, however, this discussion ofcutter coverage can also apply to cutter wheels having more than twogroupings of cutters. FIGS. 49 and 50 illustrate that the cutter tips4006 are configured in a manner such that only the cutter tips 4006 willinitially engage and contact the material being cut, regardless ofwhether the operator is sweeping the cutter wheel 3600 from side toside, or plunging the cutter wheel 3660 straight into the material.Notice how the leg portions 4200, 4204 of the side-mounted cutter tips4006 have a length in a direction extending away from their respectivecrown portions 4208 (i.e., toward the drive plate 3602) that is longenough to ensure that no gap in cutting coverage exists between theside-mounted cutter tips 4006 and the plunge cutter tip 4006 duringrotation of the cutter wheel 3600. This helps to prevent wear on thecutter body 4001 and the wear plates 3604 that could occur if a gap inthe cutter tip coverage existed. The overall design of the cutter tips4006, along with the thicknesses of the drive plate 3602 and the wearplates 3604 is considered to ensure this complete cutter coverageprovided by the cutter tips 4006 of each grouping of cutters 3616.Furthermore, this complete cutter coverage is provided with only asingle cutter tip design. In other words, complete cutter coverage isprovided using the same cutter 3616, having the same cutter tip 4006,for all of the cutter locations (i.e., plunge or side-mount) on thecutter wheel 3600.

FIGS. 51-53 illustrate yet another cutter wheel 5100 embodying theinvention. The cutter wheel 5100 is illustrated as being a laminatedcutter wheel and is similar in many respects to the cutter wheel 114,discussed above with respects to FIGS. 2-5, the cutter wheel 900,discussed relative to FIGS. 9-12, the cutter wheel 2000 discussed aboverelative to FIGS. 20-22, the cutter wheel 2300 discussed above relativeto FIGS. 23-25, and the cutter wheel 3600, discussed relative to FIGS.36-50, and may include any of the above discussed features of cutterwheel 114, 900, 2000, 2300, or 3600. Similar parts have been givensimilar part numbers of the 5100 series. The same description set forthabove for the cutter wheels 114, 900, 2000, 2300, and 3600 can applyequally to the cutter wheel 5100 and will not be repeated herein.

The cutter wheel 5100 is designed for larger machines than the cutterwheel 3600, however, it utilizes the same style of cutting tooth (albeitperhaps larger in size). As such, the above description of the cutters3616 applies equally for the cutter wheel 5100 and will not be repeated.The cutter wheel 5100 includes a thicker drive plate 5102, and as such,utilizes two cutters 5116, mounted side-by-side, at the plunge cutterlocations. At a first plunge cutter location 5200, a mount 5121 a iswelded to the drive plate 5102. The mount 5121 a includes twoboss-receiving features 5223 spaced apart so as to receive two cutters5116 in side-by-side relationship as shown. A second, adjacent plungecutter location 5204 utilizes a different mount 5121 b that has theboss-receiving features spaced further apart and located on surfaces ofthe mount 5121 b that are angled relative to one another such that twomounted cutters 5116 will be spaced apart or offset axially from oneanother, and will also be angled or canted relative to one another andrelative to the drive plate 5102. This arrangement of plunge cuttersfacilitates complete cutter coverage for the thicker cutter wheel 5100.

FIG. 53 illustrates a mounted pair of cutters 5116 (and is alsorepresentative of a mounted pair of the cutters 3616). It is again seenthat the boss 5304, and more specifically the engagement between thereaction surfaces and the boss-receiving feature 5223, opposes thedominant force vector to maintain the position of the cutter 5116relative to the boss-receiving feature 5223 on the wear plates 5104 (oron the mounts 3121 a, 5121 b). As described above with respect to thecutter 3616, the reaction surfaces further operate to minimize shearforce on the fastener 5118 because the fastener 5118 does not directlycontact the apertures in the drive plate 5102 or the wear plates 5104through which it extends (see FIG. 53). As illustrated, the apertures inthe wear plates 5104 are smaller than the corresponding aperture in thedrive plate 5102. This is intentional so that even if the fasteners 5118would engage the wear plates 5104 at the wear plate apertures, thelarger holes in the drive plate 5102 would still prevent the fasteners5118 from engaging the drive plate 5102. This minimizes or eliminatesthe likelihood of the fastener holes in the drive plate 5102 becomingmisshapen or “egged out,” thereby preserving the integrity of the driveplate 5102 even though the wear plates 5104 might need to be replaced.

Changes may be made in the above methods and systems without departingfrom the scope hereof. It should thus be noted that the matter containedin the above description or shown in the accompanying drawings should beinterpreted as illustrative and not in a limiting sense. The followingclaims are intended to cover all generic and specific features describedherein, as well as all statements of the scope of the present method andsystem, which, as a matter of language, might be said to falltherebetween.

What is claimed is:
 1. A cutter configured to be mounted on arotationally driven apparatus for material reduction of an object, thecutter comprising: a first end configured to first engage the objectalong a dominant force vector; a second end opposite the first end; afirst side; and a second side opposite the first side; the cutter havinga length between the first end and the second end, and a width betweenthe first side and the second side; the cutter further including anouter side; an inner side configured to engage the rotationally drivenapparatus; an aperture extending from the outer side to the inner sidealong a fastener axis that is substantially perpendicular to thedominant force vector, the aperture configured to receive a fastener tosecure the cutter to the apparatus; and a cutter tip on the first endand having a first cutting edge extending along the first side, a secondcutting edge extending along the second side, and a third cutting edgeextending along the outer side, the cutting edges defining therebetweena cutting face of the cutter tip, the cutting face configured to definea cutting swath having a width between the first cutting edge and thesecond cutting edge as the cutter rotates with the apparatus; whereinthe first and second sides of the cutter body extend in a direction ofthe dominant force vector and taper from the first end toward the secondend such that the first end has a greater width than the second end. 2.The cutter of claim 1, wherein the width of the cutting swath isvariable and increases in a direction from the inner side toward theouter side.
 3. The cutter of claim 1, wherein the cutter tip includes afirst leg portion extending along the first side and including the firstcutting edge, a second leg portion extending along the second side andincluding the second cutting edge, and a crown portion extending betweenthe first and second leg portions and including the third cutting edge.4. The cutter of claim 3, wherein the cutter tip includes a first cuttertip segment defining the first leg portion and part of the crownportion, and a second cutter tip segment defining the second leg portionand part of the crown portion.
 5. The cutter of claim 3, wherein thecrown portion defines a concavity in the outer side.
 6. The cutter ofclaim 5, wherein the outer side of the cutter between the aperture andthe cutter tip includes a concavity conforming in shape to the concavitydefined by the crown portion of the cutter tip.
 7. The cutter of claim1, wherein the first and second sides each include a projecting ridgeextending between the first end and the second end.
 8. The cutter ofclaim 1, wherein the aperture is configured such that the fastener axisis parallel to an axis of rotation of the rotationally driven apparatuswhen the cutter is mounted on the rotationally driven apparatus.
 9. Thecutter of claim 1, wherein the inner side includes a mounting surfaceportion configured to engage a first surface of the apparatus; and aplurality of reaction surface portions configured to engage matingsurfaces of the apparatus and disposed between the mounting surfaceportion and the first end, at least two of the plurality of reactionsurface portions being angled relative to one another such that theplurality of reaction surface portions extend along the width from thefirst side to the second side in a non-planar manner.
 10. The cutter ofclaim 1, wherein the cutter includes a body defining a ledge adjacentthe first end, and wherein the cutter tip is supported on the ledge. 11.A cutter configured to be mounted on a rotationally driven apparatus formaterial reduction of an object, the cutter comprising: a first endincluding a cutting tip configured to first engage the object along adominant force vector; a second end opposite the first end; a firstside; and a second side opposite the first side; the cutter having alength between the first end and the second end, and a width between thefirst side and the second side; the cutter further including an outersurface; and an inner surface having portions configured to engage therotationally driven apparatus, the inner surface including a mountingsurface portion configured to engage a first surface of the apparatus;and a plurality of reaction surface portions configured to engage matingsurfaces of the apparatus and disposed between the mounting surfaceportion and the first end, at least two of the plurality of reactionsurface portions being angled relative to one another such that theplurality of reaction surface portions extend along the width from thefirst side to the second side in a non-planar manner; and an apertureextending from the outer surface to the mounting surface portion along afastener axis that is substantially perpendicular to the mountingsurface portion and to the dominant force vector, the apertureconfigured to receive a fastener to secure the cutter to the apparatus.12. The cutter of claim 11, wherein the plurality of reaction surfaceportions include an inner surface portion and a transition surfaceportion that intersects the inner surface portion at an angle of between100 and 160 degrees.
 13. The cutter of claim 12, wherein the transitionsurface portion is a first transition surface portion that intersectsthe inner surface portion at a first end of the inner surface portion,and wherein the plurality of reaction surface portions further includesa second transition surface portion that intersects the inner surfaceportion at a second end of the inner surface portion and at an angle ofbetween 100 and 160 degrees.
 14. The cutter of claim 13, wherein thefirst and second transition surface portions are symmetrical about alongitudinal axis of the cutter.
 15. The cutter of claim 11, wherein thecutter includes a relief notch at an intersection of the reactionsurface portions and the mounting surface portion.
 16. The cutter ofclaim 11, wherein the inner surface of the cutter includes a boss at thefirst end, the boss having a first surface at the first end and a secondsurface facing the second end, the second surface defining the pluralityof reaction surface portions.
 17. The cutter of claim 16, wherein thefastener axis is offset from the boss such that the fastener axis is ina non-intersecting relationship with the boss.
 18. The cutter of claim16, wherein the boss has a first dimension measured along the length anda second dimension measured along the width, and wherein the seconddimension is larger than the first dimension.
 19. The cutter of claim11, wherein the mounting surface portion defines a plane.
 20. The cutterof claim 11, wherein the dominant force vector is generallyperpendicular to at least one of the plurality of reaction surfaceportions and is generally parallel to the mounting surface portion. 21.A rotating cutting assembly comprising: a wheel configured to be mountedon a rotationally driven apparatus for material reduction of an object;a cutter removably coupled to a side surface of the wheel, the cutterincluding a first end configured to first engage the object along adominant force vector; a second end opposite the first end; a firstside; and a second side opposite the first side; the cutter having alength between the first end and the second end, and a width between thefirst side and the second side; the cutter further including an outerside; an inner side configured to engage the wheel; an apertureextending from the outer side to the inner side along a fastener axisthat is substantially perpendicular to the dominant force vector, theaperture configured to receive a fastener to secure the cutter to thewheel; and a cutter tip on the first end and having a first cutting edgeextending along the first side, a second cutting edge extending alongthe second side, and a third cutting edge extending along the outerside, the cutting edges defining therebetween a cutting face of thecutter tip, the cutting face configured to define a cutting swath havinga width between the first cutting edge and the second cutting edge asthe cutter rotates with the apparatus; wherein no portion of the firstside or the second side extends outside the width of the cutting swath;and wherein the wheel further includes a gullet formed therein andadjacent the cutter, and wherein the gullet includes a straight segmentdefining a first leg of the gullet positioned adjacent the cutter tip,and an arcuate segment defining a second leg of the gullet.
 22. Therotating cutting assembly of claim 21, wherein the straight segment ofthe gullet extends substantially radially relative to the wheel.
 23. Therotating cutting assembly of claim 21, wherein the cutting edges of thecutter tip define a cutter plane, and wherein the cutter planeintersects the wheel along a line that is substantially parallel to thestraight segment of the gullet.
 24. The rotating cutting assembly ofclaim 21, wherein the gullet has a depth measured from an outerperiphery of the wheel adjacent the gullet, and wherein the straightsegment extends to a deepest portion of the gullet.
 25. The rotatingcutting assembly of claim 21, wherein the gullet has a depth measuredfrom an outer periphery of the wheel adjacent the gullet, and whereinthe gullet has a depth of at least 1-1.5 times a maximum width of thecutter.
 26. The rotating cutting assembly of claim 21, wherein the innersurface of the cutter includes a boss at the first end, the boss havinga first surface at the first end and a second surface facing the secondend, the second surface being engaged with the wheel.
 27. The rotatingcutting assembly of claim 26, wherein the wheel includes a drive plateand a wear plate coupled to a side of the drive plate, and wherein thesecond surface of the boss engages the wear plate.
 28. A cutterconfigured to be mounted on a rotationally driven apparatus for materialreduction of an object, the cutter comprising: a first end configured tofirst engage the object along a dominant force vector; a second endopposite the first end; a first side; and a second side opposite thefirst side; the cutter having a length between the first end and thesecond end, and a width between the first side and the second side; thecutter further including an outer side; an inner side configured toengage the rotationally driven apparatus; an aperture extending from theouter side to the inner side along a fastener axis that is substantiallyperpendicular to the dominant force vector, the aperture configured toreceive a fastener to secure the cutter to the apparatus; and a cuttertip on the first end and having a first cutting edge extending along thefirst side, a second cutting edge extending along the second side, and athird cutting edge extending along the outer side, the cutting edgesdefining therebetween a cutting face of the cutter tip, the cutting faceconfigured to define a cutting swath having a width between the firstcutting edge and the second cutting edge as the cutter rotates with theapparatus; wherein the width of the cutting swath is variable andincreases in a direction from the inner side toward the outer side.